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

G345275 en

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