Ford Falcon. Manual — part 291
310-00-5 Fuel
System 310-00-5
DESCRIPTION AND OPERATION (Continued)
carbon canister
control valve when engine operating conditions are
favourable.
canister purge control valve
When the purge valve is open, manifold vacuum is
fuel tank filler cap
applied to the canister. Fresh air is drawn through the
These components form the Fuel Expansion and
canister from the corrugated nylon tube on the
Vapour Collection System and the Vapour Vent and
atmospheric port. As the fresh air is drawn through
Storage System.
the carbon bed it releases the vapour from the
granules and carries it into the engine to be
Fuel Expansion and Vapour Collection
consumed in the combustion process.
All fuel tanks are is designed to leave a volume void
or space above the fuel when the tank is filled to
Filler Cap
capacity:
The filler cap incorporates a two way
pressure/vacuum relief valve. The cap functions as a
Sedan 68 litres
check valve under normal operating conditions. It
Wagon 69 litres
allows air to enter the tank as fuel is used while
Ute 78 lites
preventing vapours to escape to the atmosphere. IT
Filled to capacity is generally when the fuel bowser
IS VERY IMPORTANT THAT THE CORRECT CAP
nozzle shuts off. This space allows for the expansion
IS USED.
of the fuel and the collection of vapours.
The cap opening pressure have been varied since the
Trickle filling the tank beyond rated capacity will
EA Falcon in 1988 to improve vapour management.
damage the emission system. To prevent this, DO
To indicate the difference the colour of the cap was
NOT fill past the first bowser shut off click.
changed.
Black. .. 2.5 kPa 1988 to 1998
Vapour Vent and Storage
Grey. ... 4.5 kPa 1998 to 2002
Sedan: In addition to the fuel vapours generated in
the tank the vapour generated during refueling are
Green. . 11 kPa 2002
vented through the Fuel Limit Vent Valve (FLVV) and
the Roll Over Valve (ROV) to the carbon canister
CAUTION: It is very important that the correct
where they are stored prior to being consumed in the
cap is used.
engine.
Fuel Filters
Pressure in the tank will force vapour into the canister
The FLVV and the ROV prevents the canister from
To prevent the fuel injectors becoming clogged or
receiving liquid fuel in the event of a vehicle roll over
contaminated with foreign material, the fuel system
accident.
contains four levels of filtering:
The FLVV controls the rated liquid capacity of the
Fuel Pump: A filter screen is mounted on the
tank.
intake side of the fuel pump. The filter is part of
the assembly and cannot be replaced separately.
Wagon & Ute: The fuel vapours generated in the tank
are vented through the vapour line to the carbon
Fuel Filter Assembly: The fuel filter assembly is
canister where they are stored prior to being
located in the fuel supply line between the fuel
consumed in the engine.
pump and the fuel rail. The fuel filter assembly
must be periodically replaced according to the
Pressure in the tank will force vapour into the canister
maintenance schedule.
via the central spigot on the pump unit. The upper
filler neck is vented via a nylon line back to the tank.
Fuel Pressure Regulator: A filter is located on
the inlet side of the fuel pressure regulator. The
A rollover valve is installed in the central spigot. The
filter is part of the assembly and cannot be
valve prevents the canister from receiving liquid fuel in
replaced separately.
the event of a vehicle roll over accident.
Fuel Injectors: A mesh screen on the inlet side of
Carbon Canister
the fuel injector prevents foreign debris and
The canister contains a quantity of activated carbon
materials from entering the fuel injector
granules for storage of fuel vapours and filters to
mechanism. The filter is part of the assembly and
prevent ingress of particulate matter into the engine. It
cannot be replaced separately.
is mounted on or near the tank.
Fuel system shut off switch
Pressure and vacuum in the fuel tank forces vapours
All Barra models are fitted with a switch that cuts off
through the vapour line into the canister where it is
fuel supply to the engine in the event of an accident.
adsorbed by the carbon granules. Purging of the
Sudden vibrations such as collisions when parking
vapours from the canister is controlled by a signal
may also activate this switch.
from the PCM that varies the duty cycle (frequency of
opening and closing) of the solenoid type purge
G345274 en
310-00-6 Fuel
System 310-00-6
DESCRIPTION AND OPERATION (Continued)
Fuel pressure regulator
The fuel pressure regulator works with the fuel pump
to maintain a steady pressure relationship between
the fuel line side of the injectors and the intake
manifold. The regulator is a spring loaded diaphragm.
The spring keeps the appropriate amount of pressure
in the fuel system. When there is a high vacuum in
the intake manifold, such as at high rpm, the pressure
in the fuel system must be reduced. When there is
low pressure in the intake manifold, such as at low
speed or full throttle operation, the pressure in the fuel
line must be increased. In order to maintain desired
fuel pressure, excess fuel is returned to the tank by a
separate line from the pressure regulator.
G345274 en
310-00-7 Fuel
System 310-00-7
DIAGNOSIS AND TESTING
Ensure that there is fuel in the tank.
Fuel System
NOTE: If Diagnostic Trouble Code P0230 is displayed
Inspection and Verification
during the PCM Self Test the fuel pump relay
actuating circuit is faulty. This fault must be rectified
before carrying any further fuel delivery tests.
WARNING: Fuel supply lines will remain
To carry out pressure and volume tests it is first
pressurized for long periods of time after engine
necessary to install a remote control switch in the
or pump shut down. Use care to prevent personal
power line to the pump. Detach the loom connector
injury or combustion of fuel when disconnecting
from the base of the fuel pump relay. Connect the
fuel lines.
switch across terminals 57 (BK) and 787 (BK/Y) of the
loom connector.
CAUTION: Do not run the fuel pump in a dry
condition, to do so will damage internal
components of the pump.
Symptom Chart
NOTE: Please note the following assumptions:
Battery voltage has been checked and verified as 12V
Starter motor is cranking
DTC 0232 on PCM not flagged
Condition
Source
Action
Able to crank (ie starter motor working)
Fuel Pump
Go to Pinpoint test A
Fuel shut off switch
but engine does not catch
Fuel relay in PDB
Wiring, circuitry
Ignition coils, spark plugs
Pinpoint Tests
PINPOINT TEST A : ABLE TO CRANK (IE. STARTER MOTOR WORKING) BUT ENGINE DOES NOT
CATCH
Test Step
Result / Action to Take
A1
CHECK IF FUEL SHUT OFF SWITCH IS "ACTIVATED"
(O/C BETWEEN FUEL PUMP AND POWER FROM PDB)
Turn key to ACC or ON.
Yes
Go to A2
Is fuel shut off switch activation light on cluster illuminated?
No
Press fuel shut off switch button, then retry
starting vehicle. Fuel shut off switch is accessed
via scuff plate in front passenger foot well.
A2
LISTEN FOR FUEL PUMP OPERATION
Turn key to ON and for fuel pump. Fuel pump should make buzzing or
Yes
clicking noise when operational.
Check ignition coils and spark plugs
NB: two people are required for this test: 1 person to turn key, 1
No
person to listen to fuel pump under car.
Go to A3
Is fuel pump operational?
A3
CHECK FUEL FUSE IN PDB
Check if fuel fuse in PDB is blown.
Yes
Replace fuel fuse with a new fuse, then retry
Is fuel fuse in PDB blown?
starting vehicle.
No
Go to A4
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310-00-8 Fuel
System 310-00-8
DIAGNOSIS AND TESTING (Continued)
Test Step
Result / Action to Take
A4
CHECK VOLTAGE SUPPLY TERMINAL OF FUEL RELAY
SOCKET IN PDB
Remove fuel relay from PDB
Yes
Check wiring between fuel fuse and fuel relay
Measure voltage of fuel relay socket terminal (on PDB) circuit 1059 to socket terminal (on PDB) circuit 1059.
grond
No
Is 12V measured on terminal?
Go to A5
A5
CHECK PDB RELAY
Turn key to OFF position.
Yes
Replace Fuel relay and retest for correct
Place finger on fuel pump relay in PDB
operation.
Turn key to ON and feel for activation "click" from fuel relay.
No
NB: two people are required for this test: 1 person to turn key, 1
Go to A6
person to place finger on fuel relay.
Is fuel relay activating?
A6
CHECK VOLTAGE ACROSS FUEL PUMP
Check voltage across fuel pump. Refer to Section 310-00 for
Yes
instructions to access fuel pump
Problem with fuel pump. Replace fuel pump
Is voltage across fuel pump 12V?
No
Go to A7
A7
CHECK IF FUEL SHUT OFF SWITCH IS CONNECTED TO
HARNESS
Remove scuff plate in front passenger foot well.
Yes
Connect fuel shut off switch to harness, then
Is fuel shut off switch connected to harness?
retry starting vehicle.
No
Go to A8
A8
CHECK CONTINUITY OF FUEL SHUT OFF SWITCH
Disconnect fuel shut off switch.
Yes
Fuel shut off switch is faulty. Replace fuel shut
Check continuity of fuel shut off switch
off switch and retry starting vehicle.
Does fuel shut off switch function as expected?
No
Go to A9
A9
CHECK VOLTAGES SUPPLIED TO FUEL SHUT OFF
SWITCH
Measure voltage of circuit 787A at Fuel shut off switch terminal on
Yes
harness.
There is a wiring break between fuel relay
socket terminal (on PDB) and connector of fuel
Is 12V measured?
shut off switch (on harness). Repair harness and
retest for correct operation.
No
There is a wiring break between the connector
of fuel shut off switch (on harness) and fuel
pump connector (on harness). Repair harness
and retest for correct operation.
G345275 en
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