TheRedBeast01

Found and fixed the problem! Thank you to everyone on the forum for the suggestions and help. Here is what it was: The Vacuum Input Port on the old Vapor Canister Purge Valve somehow got sheared off. It was broken so clean you couldn't even tell that there was a nipple for the vacuum line on the old part. When I installed the new Vapor Canister Purge Valve I noticed the extra port, which was the Vacuum Input Port, but no hose to go with it. I found a diagram on the hood of the truck that showed where the hose should have been. I dug and found it buried near the fuel rail. It still had the broken plastic from the old Purge Valve. It's a very small red vacuum line. I plugged it back in and ran the truck. The smell is gone! Vapor Canister is purging and all is well!

Found it! There was a handy dandy diagram on the hood of the truck over my head the whole time. It took a while to trace it, but I found a very small red vacuum line and it had the broken nipple from the old Purge Valve in it. I attached it to the new and will see how it goes! I think this will do it!

I think I may have found the problem. After driving about 100 miles yesterday with the new Vapor Canister Purge Valve, there was really no difference. I compared the old part to the new and noticed that the Input Port Vacuum (To Intake Manifold) on the old part was broken off completely. The Input Port Vacuum on the Vapor Canister Purge Valve sticks out the bottom and is extremely small. I checked to see if I could find any loose and unused lines, but none. Where does this line connect into the intake? Does anyone have a part number or size? If I know where it goes, I can pick up a hose to install. I couldn't find any open ports in the back of the intake.

I swapped in a new Vapor Canister Purge Valve today. Only ran about 30 miles so far in mixed driving. The odor from the Vapor Canister has been greatly reduced, but is not all the way gone yet -- but better. I'll need to put some more miles on it to have all of the built up fumes cycle out. Right now I'm at about 1/4 tank. I will post updates.

Thanks YT90SC and ajcomputer! I think I'm going to try swapping out the valve and inspecting the lines as I go. I'll keep you posted on what happens.

Thanks for the feedback YT90SC. This truck does not have CA emissions, so there is no Vapor Canister Vent Solenoid. I do think that the Canister Purge Valve may be the culprit and I have been tempted to swap it out, but my mechanic swears that it would throw a code. I don't think it would hurt to swap in a new one. It's easy enough to do.

I’ve got an issue that both my mechanic and I can’t figure out. I have a 2001 Ford Excursion 6.8L V10. It runs like a champ, gets really good mileage for what it is, but there a strong fuel vapor smell coming from the charcoal vapor canister under the hood. You can smell it outside the truck and the smell gets pulled in through the vents - have to use Max AC recirc. After checking and testing, I can confirm that the fuel vapor smell is coming from the charcoal canister and not anywhere else on the engine. The smell gets worse as the tank drains: Full Tank - Almost No Smell; Half Tank - Strong Smell; 1/4 Tank - Very Strong Smell. Here is all that we have tried. Replaced Fuel Cap (Genuine Ford) Visually inspected the Evap Lines - Look Good Visually inspected Fuel Line and Fuel Filter - Look Good Checked the Fuel System for Leaks - None Pressure Tested the Fuel System - No Leaks Ran Multiple Smoke Tests on Evap System - No Leaks Checked the Computer for Codes - No Codes Replaced the Charcoal Vapor Canister (Genuine Ford) We are totally stumped. I searched all the forums and can find issues with plugs, fuel injector o-rings, and leaks, but this has all be checked. Any help would be appreciated!