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310-01A-1 Fuel Tank and Lines — 2.5L Duratec-HE (122kW/165PS) - MI4 310-01A-1 SECTION 310-01A Fuel Tank and Lines — 2.5L Duratec-HE (122kW/165PS) - MI4 VEHICLE APPLICATION: 2011.50 Ranger CONTENTS PAGE DESCRIPTION AND OPERATION Fuel Tank and Lines 310-01A-2 REMOVAL AND INSTALLATION Fuel Tank Fuel Tank Fuel Tank Filler Pipe Fuel Tank Filler Pipe Fuel Filter Fuel Pump and Sender Unit Fuel Level Sender 310-01A-6 310-01A-9 310-01A-12 310-01A-14 310-01A-15 310-01A-16 310-01A-17 310-01A-2 Fuel Tank and Lines — 2.5L Duratec-HE (122kW/165PS) - MI4 310-01A-2 DESCRIPTION AND OPERATION Fuel Tank and Lines Vehicles with petrol engine Item Description Item Description Fuel filter Vapor emission valve Fuel tank Vapor line from canister Supply line to injection rail 2011.50 Ranger Fuel is stored in the fuel tank and delivered to the fuel injectors by means of a submersed fuel pump through an inline fuel filter G1274025en 310-01A-3 Fuel Tank and Lines — 2.5L Duratec-HE (122kW/165PS) - MI4 310-01A-3 DESCRIPTION AND OPERATION Fuel tank and lines Item Description Item Description Fuel tank filler neck Return line from fuel filter to fuel tank Fuel tank filler hose Atmospheric vent line from canister Fuel tank vent valve to evaporative emission canister vapor line Fuel pump and sender unit 10 Fuel tank Vapor line from canister to purge valve 11 Tank protector Supply line from fuel tank to fuel filter 12 Evaporative emission canister Fuel filter 13 Fuel tank breather hose 2011.50 Ranger G1274025en Fuel Tank and Lines — 2.5L Duratec-HE (122kW/165PS) - MI4 310-01A-4 310-01A-4 DESCRIPTION AND OPERATION Fuel return system Item Description Fuel filter Fuel line fuel return T-piece Fuel pressure regulator Fuel rail Fuel return line Fuel tank Fuel jet pump Fuel pump Fuel pump and sender unit 10 Fuel pump and sender unit flange fuel to the fuel pressure regulator located in the fuel pump and sender unit, via the return port on the fuel pump and sender unit flange By allowing excess fuel to return to the tank via the fuel pressure regulator, a constant pressure can be maintained at the fuel rail and injectors Fuel tank vent valves The fuel pressure at the fuel injectors is controlled by a fuel pressure regulator that is integral to the fuel pump and sender unit Fuel is pumped from the fuel tank to the fuel filter via the fuel supply line mounted on the left-hand chassis rail From the fuel filter, fuel is then delivered to the fuel rail A "T" piece is fitted to the fuel supply line on the clean side of the filter The T piece directs excess 2011.50 Ranger Unlike the fuel tank fitted to vehicles with diesel engines, the petrol fuel tank does not allow fuel vapor to vent to the atmosphere Instead the fuel vapor is collected in the evaporative emission canister until the correct driving conditions permit the fuel vapor to be burnt in the engine combustion G1274025en 310-01A-5 Fuel Tank and Lines — 2.5L Duratec-HE (122kW/165PS) - MI4 310-01A-5 DESCRIPTION AND OPERATION chambers This reduces the overall emissions from the vehicle If the fuel tank becomes inverted, the fuel tank vent valves close preventing the evaporative emission canister being filled with fuel If the fuel tank vent valves, fuel vapor lines or the evaporative emission canister become restricted, vehicle performance will become impaired The inability of the fuel tank to substitute the fuel demanded by the fuel pump with air, will create a negative pressure in the fuel tank The fuel filler cap has both vacuum and pressure relief valves to prevent excess vacuum or pressure from causing deformation of the fuel tank Fuel pump and sender Unit and seal.The fuel pump is attached to the fuel pump and sender unit flange by spring loaded guide bars, which ensure that the fuel pump is seated against the base of the fuel tank when installed The fuel level sender consists of a mechanical float attached to a variable resistor card by means of a rigid wire lever The resistor card has two electrical elements One element is solid and one element is a variable resistor The resistance value created by the resistor card is sent to the body control module (BCM) through a hard wired circuit The BCM distributes the information from the fuel pump and sender to the instrument cluster and the powertrain control module (PCM) using the controller area network (CAN) circuits.The fuel pump and sender unit can be sensitive to contaminated fuel Contaminated fuel can affect the electrical continuity and give false fuel level readings The fuel pump and sender resistor card can be susceptible to contaminated fuel, which can affect electrical continuity This condition is normally temporary and self-rectifying If the fuel pump and sender has been removed, moving the rigid wire lever from empty to full a minimum of 10 times will normally be as effective as installing a new fuel pump and sender The most common symptom of contamination occurs after refuelling where the electrical contact moves to an area of the resistor card which has not been used for several days This results in a very slow movement of the fuel gauge pointer from empty to full over approximately 15 minutes In more extreme cases where the resistor card resistance is continuously outside the permitted range for more than 33 seconds, a (diagnostic trouble code) DTC will be set in the BCM and the fuel gauge pointer will fall to its key-off position Item Description Fuel pump and sender unit locking ring Fuel pump and sender unit sealing ring Sock filter Fuel jet pump Fuel pump Fuel level sensor resistor card The fuel pump supplies fuel to the fuel charging system at a constant regulated pressure The fuel pressure is controlled by the fuel pressure regulator, built into the fuel pump fuel return circuit The fuel pump and sender also incorporates a fuel jet pump Fuel from the fuel charging system is passed through a venturi in the jet pump which causes a pressure drop across an open orifice This draws in fuel through the base of the unit which then passes through the sock filter to the fuel pump The fuel pump and sender unit is located in the top of the fuel tank and is retained by a locking ring 2011.50 Ranger G1274025en 310-01A-6 Fuel Tank and Lines — 2.5L Duratec-HE (122kW/165PS) - MI4 310-01A-6 REMOVAL AND INSTALLATION Fuel Tank General Equipment Retaining Strap Transmission Jack Removal NOTE: Removal steps in this procedure may contain installation details Duratec-HE (122kW/165PS) - MI4, General Procedures) NOTE: Vehicles with load box Refer to: Fuel System Pressure Release (310-00 Fuel System - General Information 2.5L Duratec-HE (122kW/165PS) - MI4, General Procedures) Refer to: Fuel Tank Draining (310-00 Fuel System - General Information - 2.5L Duratec-HE (122kW/165PS) - MI4, General Procedures) WARNING: Fuel may still be present in the fuel tank after draining Refer to: Quick Release Coupling (310-00 Fuel System - General Information - 2.5L 2011.50 Ranger 4x4 Torque: 15 Nm G1274030en 310-01A-7 Fuel Tank and Lines — 2.5L Duratec-HE (122kW/165PS) - MI4 310-01A-7 REMOVAL AND INSTALLATION All vehicles General Equipment: Transmission Jack General Equipment: Retaining Strap Torque: 48 Nm CAUTION: Make sure that no strain General Equipment: Transmission Jack is placed on the wiring harness NOTE: Slowly lower the fuel tank to access the fuel pump and sender unit electrical connector General Equipment: Retaining Strap NOTE: Make sure that the clamp is installed to the same orientation as when removed Refer to: Quick Release Coupling (310-00 Fuel System - General Information - 2.5L 2011.50 Ranger G1274030en 310-01A-8 Fuel Tank and Lines — 2.5L Duratec-HE (122kW/165PS) - MI4 310-01A-8 REMOVAL AND INSTALLATION Duratec-HE (122kW/165PS) - MI4, General Procedures) WARNING: Make sure that all fuel connections are checked for leaks CAUTION: If the fuel tank has been filled with the wrong type of fuel, the engine must not be started before the fuel system is cleaned NOTE: Make sure that the correct type of fuel is added after the tank installation To install, reverse the removal procedure Installation NOTE: Make sure that the clamp is installed to the same orientation as when removed Refer to: Quick Release Coupling (310-00 Fuel System - General Information - 2.5L Duratec-HE (122kW/165PS) - MI4, General Procedures) CAUTION: Make sure that the insulator pads are correctly positioned on the fuel tank 2011.50 Ranger G1274030en 310-01A-9 Fuel Tank and Lines — 2.5L Duratec-HE (122kW/165PS) - MI4 310-01A-9 REMOVAL AND INSTALLATION Fuel Tank General Equipment Retaining Strap Transmission Jack Removal NOTE: Removal steps in this procedure may contain installation details NOTE: Vehicles with aluminium tray Refer to: Fuel System Pressure Release (310-00 Fuel System - General Information 2.5L Duratec-HE (122kW/165PS) - MI4, General Procedures) Refer to: Fuel Tank Draining (310-00 Fuel System - General Information - 2.5L Duratec-HE (122kW/165PS) - MI4, General Procedures) WARNING: Fuel may still be present in the fuel tank after draining Refer to: Quick Release Coupling (310-00 Fuel System - General Information - 2.5L Duratec-HE (122kW/165PS) - MI4, General Procedures) 2011.50 Ranger G1520805en 310-01A-10 Fuel Tank and Lines — 2.5L Duratec-HE (122kW/165PS) - MI4 310-01A-10 REMOVAL AND INSTALLATION 4x4 All vehicles Torque: 15 Nm General Equipment: Transmission Jack General Equipment: Retaining Strap Torque: 48 Nm Refer to: Quick Release Coupling (310-00 Fuel System - General Information - 2.5L Duratec-HE (122kW/165PS) - MI4, General Procedures) 2011.50 Ranger Installation Refer to: Quick Release Coupling (310-00 Fuel System - General Information - 2.5L Duratec-HE (122kW/165PS) - MI4, General Procedures) G1520805en 310-01A-11 Fuel Tank and Lines — 2.5L Duratec-HE (122kW/165PS) - MI4 310-01A-11 REMOVAL AND INSTALLATION CAUTION: Make sure that the insulator pads are correctly positioned on the fuel tank WARNING: Make sure that all fuel connections are checked for leaks CAUTION: If the fuel tank has been filled with the wrong type of fuel, the engine must not be started before the fuel system is cleaned NOTE: Make sure that the correct type of fuel is added after the tank installation To install, reverse the removal procedure 2011.50 Ranger G1520805en 310-01A-12 Fuel Tank and Lines — 2.5L Duratec-HE (122kW/165PS) - MI4 310-01A-12 REMOVAL AND INSTALLATION Fuel Tank Filler Pipe Removal NOTE: Removal steps in this procedure may contain installation details NOTE: Vehicles with load box Remove the left-hand rear wheel and tire Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation) Refer to: Gasoline and Gasoline-Ethanol Fuel Systems Health and Safety Precautions (100-00 General Information, Description and Operation) NOTE: Make sure that the fuel tank is no more than 3/4 full 2011.50 Ranger G1274031en 310-01A-13 Fuel Tank and Lines — 2.5L Duratec-HE (122kW/165PS) - MI4 310-01A-13 REMOVAL AND INSTALLATION NOTE: Make sure that the clamp is installed to the same orientation as when removed Torque: 11 Nm NOTE: For removal of the fuel filler pipe and vent hose Refer to: Fuel Tank (310-01 Fuel Tank and Lines - 2.5L Duratec-HE (122kW/165PS) MI4, Removal and Installation) Installation To install, reverse the removal procedure 2011.50 Ranger G1274031en 310-01A-14 Fuel Tank and Lines — 2.5L Duratec-HE (122kW/165PS) - MI4 310-01A-14 REMOVAL AND INSTALLATION Fuel Tank Filler Pipe Removal NOTE: Removal steps in this procedure may contain installation details Torque: 11 Nm NOTE: Vehicles with aluminium tray Refer to: Gasoline and Gasoline-Ethanol Fuel Systems Health and Safety Precautions (100-00 General Information, Description and Operation) WARNING: Make sure that the fuel tank is no more than 3/4 full NOTE: Make sure that the clamp is installed to the same orientation as when removed NOTE: Make sure that the clamp is installed to the same orientation as when removed Installation To install, reverse the removal procedure 2011.50 Ranger G1519139en 310-01A-15 Fuel Tank and Lines — 2.5L Duratec-HE (122kW/165PS) - MI4 310-01A-15 REMOVAL AND INSTALLATION Fuel Filter Removal NOTE: Removal steps in this procedure may contain installation details Refer to: Fuel System Pressure Release (310-00 Fuel System - General Information 2.5L Duratec-HE (122kW/165PS) - MI4, General Procedures) WARNING: Be prepared to collect escaping fluids NOTE: Make sure that the fuel filter is fully installed into the fuel filter retaining bracket Observe the direction of flow arrow on the fuel filter Refer to: Quick Release Coupling (310-00 Fuel System - General Information - 2.5L Duratec-HE (122kW/165PS) - MI4, General Procedures) Torque: 25 Nm Installation To install, reverse the removal procedure 2011.50 Ranger G1274032en 310-01A-16 Fuel Tank and Lines — 2.5L Duratec-HE (122kW/165PS) - MI4 310-01A-16 REMOVAL AND INSTALLATION Fuel Pump and Sender Unit Special Tool(s) 310-037 Remover/Installer, Fuel Tank Sender Unit Removal Refer to: Fuel Tank (310-01 Fuel Tank and Lines - 2.5L Duratec-HE (122kW/165PS) MI4, Removal and Installation) CAUTION: Take extra care not to damage the fuel tank level sensor float and arm Special Tool(s): 310-037 Installation CAUTION: Take extra care not to damage the fuel tank level sensor float and arm NOTE: Make sure that the seal is correctly located NOTE: Make sure that the installation marks are aligned To install, reverse the removal procedure 2011.50 Ranger G1274033en 310-01A-17 Fuel Tank and Lines — 2.5L Duratec-HE (122kW/165PS) - MI4 310-01A-17 REMOVAL AND INSTALLATION Fuel Level Sender Removal NOTE: Removal steps in this procedure may contain installation details CAUTION: Take extra care not to damage the fuel tank level sensor float and arm Refer to: Fuel Pump and Sender Unit (310-01 Fuel Tank and Lines - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation) CAUTIONS: Take extra care when handling the wiring terminals Make sure that the wiring terminals are not bent or damaged On both sides CAUTION: Take extra care not to damage the clips Installation 1 CAUTION: Note the position of the components before removal 2011.50 Ranger CAUTION: Make sure that the wiring terminals are not bent or damaged Undamaged terminal clips Damaged terminal clips G1518539en 310-01A-18 Fuel Tank and Lines — 2.5L Duratec-HE (122kW/165PS) - MI4 310-01A-18 REMOVAL AND INSTALLATION WARNING: Check for correct connections after installation CAUTION: Make sure that the clips are correctly located NOTE: Make sure that the wires are installed to the same orientation as when removed Refer to: Fuel Pump and Sender Unit (310-01 Fuel Tank and Lines - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation) 2011.50 Ranger G1518539en