Ford Falcon. Manual — part 290
310-00-1 Fuel
System 310-00-1
SECTION : 310-00 Fuel System
VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS
PAGE
SPECIFICATIONS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310-00-2
DESCRIPTION AND OPERATION
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..310-00-3
Electrical Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . .310-00-4
Evaporative Emission Control System . . . . . . . . . . . . . . . . . . . . ..310-00-4
Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310-00-5
Fuel system shut off switch . . . . . . . . . . . . . . . . . . . . . . . . ..310-00-5
Fuel pressure regulator . . . . . . . . . . . . . . . . . . . . . . . . . . 310-00-6
DIAGNOSIS AND TESTING
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..310-00-7
Inspection and Verification . . . . . . . . . . . . . . . . . . . . . . . . ...310-00-7
Symptom
Chart
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310-00-7
Pinpoint
Tests
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..310-00-7
GENERAL PROCEDURES
Pump Operation Check . . . . . . . . . . . . . . . . . . . . . . . . . . ..310-00-9
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .310-00-9
Fuel Flow (Volume) Test . . . . . . . . . . . . . . . . . . . . . . . . . . 310-00-9
Draining Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310-00-10
Purge Control Valve Testing . . . . . . . . . . . . . . . . . . . . . . . . 310-00-10
REMOVAL AND INSTALLATION
Fuel Tank (Sedan) . . . . . . . . . . . . . . . . . . . . . . . . . . . ...310-00-11
Fuel Tank (Wagon) . . . . . . . . . . . . . . . . . . . . . . . . . . . ..310-00-11
Fuel Tank (Ute) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310-00-11
In — Line Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .310-00-12
Fuel Supply and Fuel Return Lines . . . . . . . . . . . . . . . . . . . . . .310-00-12
Vapour Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310-00-14
Carbon Canister . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...310-00-14
Fuel Module - Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . 310-00-15
Sender Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .310-00-16
Fuel Shut Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 310-00-17
310-00-2 Fuel
System 310-00-2
SPECIFICATIONS
General Specifications
Description
Nm
Description
Specification
LPG Idle Solenoid to Converter
16
Fuel Tank Capacities — Total
LPG Converter to Mounting Bracket
7
Sedan
68 Litres
LPG Tank to Floor Mounting Bolts
50
(Sedan)
Wagon
69 Litres
LPG Tank to Floor Mounting Studs
50
Ute
78 Litres
(Wagon)
Single Fuel LPG
LPG Service Valve to Tank
5
LPG Fuel Tank
Manufactured by APA
LPG AFL to Tank
5
Industries
Capacity:
LPG Pressure Relief Valve
60
Sedan 93L (usable)
LPG Gauge (AXIOM)
5
Wagon 116L (usable)
Ute 92L (usable)
LPG Fuel Sender
0-176 ohms
LPG Pressure Relief
Relief Pressure: 2.55
Valve
MPa
LPG Service Line
Bundy-Tube - Performed
8mm
Diameter (with flexible
pressure)
hose at tank end on
sedan)
LPG Converter and Filter
VIALLE - FS Type
Lock Off Assembly
(Special)
LPG Mixer Assembly
Tickford - LPG Fuel
PCM
For detailed electrical specifications of the fuel
injection system, refer to Diagnosis and Testing, in
Section 303-14.
Fuel Pump (6 & 8 Cylinder)
Delivery (minimum)
277 cc in 10 seconds @
270 kPa,
12 Volts
Pressure at:
engine idle 225 kPa, 250 kPa I6HO
engine stationary
270 kPa, Base I6
270 kPa, Base V8
400 kPa, Turbo I6
Maximum pressure drop
10% in 10 seconds
on engine shut down
Fuel pump resistance at
< 10 ohms
loom connector:
Torque Specifications
Description
Nm
Pressure Regulator Tube Nut
27
Fuel Tank Retaining Shield – Sedan
35
Fuel Tank Retaining Strap –
28
Wagon/Ute
Sender Unit/Pump Screws – All
1.9 – 2.5
LPG Flared Connections
37
LPG Converter Bracket to Spring
Upper: 35
Tower
Lower: 15
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310-00-3 Fuel
System 310-00-3
DESCRIPTION AND OPERATION
pump assembly is mounted in the top of the tank. The
Fuel System
tank is secured to the underbody by two steel straps.
Nylon tubing with a wear resistant outer sheath form
the fuel lines. The vapour line is a nylon tube. These
lines connect the tank to the main underbody lines.
The carbon canister is mounted on the tank.
A nylon tube connects it to the central spigot of the
pump top. Another nylon line joins the canister outlet
to the main body lines. The canister has a corrugated
nylon breather hose which is clipped into a cross
member to reduce ingestion of water or dust into the
canister.
Ute
Sedan
The fuel tank on sedan models is a two piece
moulding with a separate steel filler neck (joined by
rubber hose).
The tank is located beneath the floor of the left hand
side rear passenger.
The top of the filler neck is located in the left hand
rear quarter panel. The filler neck is fixed to the side
rail with a specially coated bolt that ensures electrical
grounding to eliminate electrostatic charge.
The fuel pump assembly is mounted in the tank and is
Item
Description
accessible beneath a plastic plug under the rear
cushion on the LHS of the vehicle. The fuel level
1
Pressure/Return Lines
sender arm assy. is mounted remotely from the pump
2
Tank
on the internal baffle inside the tank. It is serviceable
3
Rear Wiring Assembly
and is electrically connected via the fuel pump wiring
The fuel tank on ute models is a one piece moulding
connector.
with an integral filler neck. It is located beneath the
Nylon tubing form the fuel lines. The vapour vent line
ute load floor, between the rear of the cabin and
is a large diameter corrugated nylon tube and is
forward of the axle.
attached to the Fuel Limit Vent Valve (FLVV) on the
top of the tank. It vents directly into the canister.
The filler neck is located in the left hand rear quarter
panel. The tank is electrically grounded via the metal
A nylon purge line then connects the canister back to
end of the filler neck to the body via a grounding wire
the main underbody lines. The canister has a
in the pump loom.
corrugated nylon breather hose which is clipped into a
cross member to reduce ingestion of water or dust
The fuel gauge sender unit and fuel pump assembly is
into the canister.
mounted in the top of the tank. The tank is secured to
the underbody by two straps.
The tank is secured to the underbody by a large
galvanized steel stamping which also acts as a shield. Nylon tubing with a wear resistant outer sheath form
The carbon canister is mounted on the body adjacent the fuel lines. The vapour line is a nylon tube. These
to the tank on the other side of the exhaust pipe and
lines connect the tank to the main underbody lines.
above the IRS.
The carbon canister is mounted on the tank. A nylon
tube connects it to the central spigot of the pump top.
Wagon
Another nylon line joins the canister outlet to the main
The fuel tank on wagon models is a one piece
body lines. The canister has a corrugated nylon
moulding with an integral filler neck. It is located
breather hose which is clipped into a cross member to
beneath the wagon load floor, rearward of the axle.
reduce ingestion of water or dust into the canister.
The top of the filler neck is located in the left hand
All models
rear quarter panel. The tank is electrically grounded
Steel tubing, 8.0 mm O/D for fuel delivery and return
via the metal end of the filler neck to the body via a
and 6.3 mm O/D for vapour, forms the main
grounding wire. The fuel gauge sender unit and fuel
underbody lines. The tubes are coated with zinc PVF
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310-00-4 Fuel
System 310-00-4
DESCRIPTION AND OPERATION (Continued)
for corrosion protection. (The main body harness also the system after the engine is shut down. The
contains one or two 4.9 mm brake lines) Elastomer
pressure retention helps to prevent hot starting
lined nitrile rubber hoses connect the engine fuel rail
problems.
to the main underbody lines.
System pressure is controlled by a pressure regulator
valve mounted on the fuel rail.
The wagon also includes a washer line to connect the
washer bottle to the windscreen nozzle.
All Falcon models have the electric pump mounted in
a Modular Reservoir Assembly (MRA). The MRA has
A fuel filter is installed in the delivery line and
an integral reservoir in which the fuel pump rests to
attached to the LHS side rail roughly in line with the B
ensure that the pump pickup is submerged in fuel at
pillar. The filter consists of a paper filtering element in
all times during extreme vehicle manoeuvres and
a stainless steel casing. The filter is a sealed unit and
attitudes when the fuel level in the tank is low.
is replaced as an assembly when required.
The reservoir is spring loaded to maintain the pump
The fuel system supplies the fuel injectors with filtered
and sender is always in contact with the bottom of the
fuel at a controlled pressure. The Powertrain Control
fuel tank (for improved low fuel usage and fuel gauge
Module (PCM) controls the fuel pump and the on/off
accuracy). A filtering element is located in the fuel
duration (pulse width) and timing of the fuel injectors.
pump reservoir to prevent contaminants which could
damage internal components of the pump. The
Fuel Injection PCM
electrical system has a fuel pump control relay which
The electronic fuel injection system supplies the
is controlled by the engine management PCM.
correct amount of fuel to the engine as required for
When the ignition switch is ’OFF’ the contacts of the
the operating conditions.
PCM and fuel pump relays are open. When the
Each cylinder has an individual fuel injector controlled ignition switch is first turned to the ON position, the
sequentially to inject the fuel at the optimum point in
PCM power relay is energized, closing its contacts.
the engine cycle. The Powertrain Control Module
With the ignition switch ’ON’ and prior to moving it to
(PCM) adjusts the fuel injection pulse width, delivering
’START’ fuel pump operation will be audible.
a precise quantity of fuel into the intake port above
The fuel pump is powered via the contacts of the fuel
the inlet valve.
pump relay. If the ignition switch is not turned to the
Fuel is injected into the cylinders in the same
START position, the PCM will open the ground circuit
sequence as the ignition firing order. As the fuel is
after approximately one second. Opening the ground
injected into a closed port, the period that each
circuit de-energizes the fuel pump relay which, in turn,
charge remains in the port is even for all cylinders,
de-energizes the fuel pump.
ensuring optimum mixture throughout the engine.
This circuitry provides for pre-pressurization of the
Fuel System Components
fuel system. When the ignition switch is turned to the
START position, the PCM operates the fuel pump
The fuel system consists of the following components.
relay to provide fuel for starting the engine while
Fuel Tank
cranking. After the engine starts and the ignition
Fuel Pump
switch is returned to the ON position, power to the
fuel pump is again supplied through the fuel pump
Fuel Supply and Return Lines
relay.
Fuel Filter
The PCM senses engine speed and shuts off the fuel
Fuel Rail
pump by opening the ground circuit to the fuel pump
Fuel Injector
relay when the engine stops or is below 120 rpm.
Fuel Pressure Regulator
Evaporative Emission Control System
Fuel Shut off Switch
A large percentage of overall emissions can consist of
Electrical Fuel Pump
petrol vapours that might escape from the fuel tank.
These evaporative losses occur not only when the
The fuel supply system incorporates an electric fuel
vehicle is operating but also when the vehicle is
pump mounted inside the fuel tank.
parked. In fact most vapours are lost when the vehicle
Both the normal 6 cylinder and 8 cylinder vehicles use is parked.
a single stage turbine type pump with a minimum
These losses have been eliminated by providing a
output, at 13 volts, of 110 litres per hour at 270 kPa.
sealed fuel tank system. With such a system, fuel
Some Tickford vehicles and high performance
vapours are trapped and directed to the engine for
vehicles may have fuel pumps with higher flow rates
burning in the normal combustion process.
and a higher pressure regulator on the engine fuel
The system consists of the following components
rail.
fuel tank
The pump has a check valve inside the outlet port.
vapour lines
The function of this valve is to maintain pressure in
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