Ford Falcon. Manual — part 292

310-00-9 Fuel

System 310-00-9

GENERAL PROCEDURES

2. Start the engine if possible and note the fuel

Pump Operation Check

pressure at idle.

1. Detach the fuel delivery line (the line coming from

If the engine cannot be started install a remote

the filter) from the fuel rail. Place the end of the

control switch at the relay.

delivery line in a container.

Operate the switch and note pressure.

Specification:

2. Switch ignition on. The pump should deliver fuel

for one second. Switch ignition off.

270 kPa Base I6

3. If the pump does not run, detach the wiring

300 kPa Base V8

connector from the pump end of the loom. On

400 kPa Turbo I6

sedan this connector is located beneath the

3. If the pressure reading is low slowly close off the

plastic cover which is under the rear seat cushion.

fuel delivery test line between the gauge and the

On wagon the connector is accessible via a

fuel rail while operating the pump. Pressure

rubber grommet in the floor of the luggage space.

should increase to at least 400 kPa.

On utes the connector may be accessible under

If pressure does not increase a faulty fuel pump is

the vehicle via the extended wiring loom.

indicated.

4. Connect a voltmeter across the loom terminals.

Switch on the ignition while observing the meter.

Fuel Flow (Volume) Test

The meter should read battery voltage for

approximately one second then drop to zero.

WARNING: Engine must be switched off

Failure to do this indicates a fault in the power

during this test.

supply circuit.

1. Disconnect the fuel return line from the steel line

5. Check the pump for continuity. Connect an

(lower dash panel) and place the end of the

ohmmeter across the terminals of the pump lead.

flexible hose into a graduated container.

(Specifications - less than 10 ohms.)

2. Operate the remote control switch for 10 seconds.

NOTE: Do not attempt to detach the fuel pump

lead from the pump bracket.

3. Remove the measuring container and check

contents against specification:277 cc.

Pressure Test

NOTE: Fuel volume must be at nominal regulated

pressure. See specifications listed in Pressure

1. ’T’ The fuel pressure gauge (refer Special Tools

Test of General Procedures in this chapter.

section) into the fuel delivery line.

Fuel System Pressure Retention

1. Operate the remote control switch for 10 seconds

and note fuel pressure.

Maximum pressure drop permissible is 10% in 10

seconds. A pressure drop in excess of this figure

indicates a leak in the pressure system.

2. Check by closing off the pressure line just before

the gauge.

No pressure drop - leak in pressure line to

pump or in non-return valve of pump.
Pressure continues to drop - leak in injectors,

pressure regulator or fuel rail connections.
To determine source of pressure leak close

off the fuel return line.

Item

Description

No pressure drop - replace pressure

1

Fuel Pressure Gauge

regulator.

2

Quick Connect Fitting

Pressure continues to drop - check fuel rail

3

Pressure Line

connections and test injectors.

3. Remove the pressure gauge and reconnect fuel

lines.

4. Check for fuel leaks.
5. Remove the remote control switch and install the

loom plug in the base of the relay.

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310-00-10 Fuel

System 310-00-10

GENERAL PROCEDURES (Continued)

Draining Fuel

If the fuel pump is operational then it should be used if

it is necessary to drain fuel from the tank. Disconnect

fuel return line at main underbody lines and attach a

transparent drain tube. Run engine to facilitate

expedient fuel removal. Air bubbles in fuel stream will

indicate low fuel level.

CAUTION: Care should be taken to ensure

fuel pump is not run dry.
1. In situations where the fuel pump is not

functioning then:

Use a nylon 5 mm OD tube carefully inserted

down the filler neck, past the tank check valve

to the bottom of the tank to siphon the fuel.

Sedan

1. With the vehicle on a level surface and the fuel

tank no more than 1/2 full it is not necessary to

remove any fuel from the tank.

Purge Control Valve Testing

1. Detach the solenoid valve.
2. Apply 250 mm Hg vacuum to one port of the

valve.

3. Apply 12V across the solenoid terminals. Vacuum

should collapse immediately. If this does not

happen, renew the valve.
NOTE: All hardware must be correctly installed

and torqued to specification.

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310-00-11 Fuel

System 310-00-11

REMOVAL AND INSTALLATION

Installation

Fuel Tank (Sedan)

1. Raise tank into straps and latch bolt/nut assy. into

Removal

body mounting brackets.

1. Drain the fuel from the fuel tank into a suitable

2. Connect the pump sender electrical loom to the

container.

pump top connector.

2. Disconnect vapour and fuel lines at main

3. Replace tank attaching bolts at filler neck and

underbody lines (QFC’s).

torque to 15Nm.

Quick Fit Connectors (QFC) is normally removed

4. Replace floor mounted air flow through vent.

by pushing the QFC further on (approx 1mm),

5. Reconnect earth lead located on filler neck.

squeezing the knurled pads together and then

pulling QFC off.

6. Torque fixing bolts at fuel tank straps to 25 - 30

Nm.

3. Disconnect balance line.

7. Reconnect

balance

line.

4. Disconnect vent and purge lines at canister

(QFC).

8. Reconnect vapour and fuel lines at main

underbody lines (QFCs).

5. Disconnect fuel filler hose and clamp.
6. Disconnect electrical connector on top of pump.

Fuel Tank (Ute)

7. Remove IRS module Refer to Section 204-02a.

Removal

8. Remove Tank shield bolts and nuts.

1. Drain the fuel from the fuel tank into a suitable

9. Lower tank carefully to ground.

container.

NOTE: Do not allow the tank to hang from the fuel

2. Raise

vehicle.

lines, wiring or filler neck during removal.

3. Remove

driveshaft.

Installation

4. Disconnect parkbrake cable at the adjuster.

1. Position the tank and shield under the vehicle and

5. Remove rear calipers.

loosly attach with bolts and nuts.

6. Remove the U bolts and spring plate on both LH

2. Align tank and shield via holes in shield and

and RH sides and slide rear axle back towards

dimples in tank.

rear of vehicle as far as possible.

3. Tighten bolts and nuts to specification.

7. Disconnect two fuel Quick Fit Connectors and the

4. Connect the wiring plug.

fuel vapor line connector at the end of the body

5. Reconnect

balance

line.

mounted fuel and brake harness assy.

6. Connect vapour and fuel lines to the main body

8. Disconnect balance line.

lines.

9. Disconnect wiring for fuel sender/pump from

7. Connect rubber hose on filler neck to tank.

upper cross-member.

8. Connect vent and purge lines to canister.

10. Remove 13 mm bolts that retain the fuel tank

straps.

9. Fill the tank, start the engine, and check all

connections for leaks.

10. Reinstall IRS.

Fuel Tank (Wagon)

Removal
1. Drain the fuel from the fuel tank into a suitable

container.

2. Disconnect vapour and fuel lines at main

underbody lines (QFC’s).

3. Disconnect balance line.
4. Remove floor mounted air flow through vent.
5. Remove tank attaching bolts at filler neck.
6. Disconnect earth lead located on filler neck.

Item

Description

7. Loosen fixing bolts at fuel tank straps.

1

Chassis

8. Support tank and lower sufficiently to allow the

2

Fuel Tank Assembly Strap

pump sender electrical loom to be disconnected.

3

Bolt

9. Lower tank and remove from vehicle.

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310-00-12 Fuel

System 310-00-12

REMOVAL AND INSTALLATION (Continued)

11. Carefully maneuver tank out of position and lower 6. Tighten the retaining strap nuts.

to the ground.

Item

Description

Item

Description

1

Neck Collar

1

Fuel Tank Assembly

2

Tank

3

Nut M8x20 Corflex

12. Remove pump, Refer to Pump Removal and

Installation in this section.

7. Fill the tank with fuel and check for leaks and fuel

Installation

gauge.

1. Loosely hang the tank in the vehicle by the tank

In — Line Filter

straps.

2. To ensure correct position of the tank when the

Removal

tank straps are fully tightened it is recommended

1. Raise the vehicle on a hoist.

that some liquid soap or detergent be smeared on

2. Remove fuel filter line retaining nipples.

the tank strap rubber insulators.

3. Loosen filter retaining clamp and slide filter

3. Reconnect the fuel pump wiring at the cross

rearward to remove from the vehicle.

member.

Installation

4. Reconnect

balance

line.

1. Install the filter in the retaining clamp with the

5. Reconnect the fuel line quick connect fittings to

arrow on the can in the direction of fuel flow.

the main fuel and brake harness on the body. The

2. Fit and tighten fuel line retaining nipples to 32

return fuel line has a piece of silver tape adjacent

Nm.

to the quick fit connector.

3. Run engine and check for fuel leaks.
4. Lower

vehicle.

Fuel Supply and Fuel Return Lines

Removal
1. With the vehicle on a level surface and the fuel

level below the bottom of the filler neck it is not

necessary to remove any fuel from the tank.

Item

Description

1

Pressure/Return Lines

2

Tank

3

Rear Wiring Assembly

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