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

Specification

LPG Idle Solenoid to Converter

Fuel Tank Capacities — Total

LPG Converter to Mounting Bracket

Sedan

68 Litres

LPG Tank to Floor Mounting Bolts

(Sedan)

Wagon

69 Litres

LPG Tank to Floor Mounting Studs

Ute

78 Litres

(Wagon)

Single Fuel LPG

LPG Service Valve to Tank

LPG Fuel Tank

Manufactured by APA

LPG AFL to Tank

Industries

Capacity:

LPG Pressure Relief Valve

Sedan 93L (usable)

LPG Gauge (AXIOM)

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

Pressure Regulator Tube Nut

Fuel Tank Retaining Shield – Sedan

Fuel Tank Retaining Strap –

Wagon/Ute
Sender Unit/Pump Screws – All

1.9 – 2.5

LPG Flared Connections

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

Pressure/Return Lines

sender arm assy. is mounted remotely from the pump

Tank

on the internal baffle inside the tank. It is serviceable

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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