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Fuel Tank and Lines — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L 310-01B-1 Duratorq-TDCi (148kW/200PS) - Puma 310-01B-1 SECTION 310-01B Fuel Tank and Lines — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma VEHICLE APPLICATION: 2011.50 Ranger CONTENTS PAGE DESCRIPTION AND OPERATION Fuel Tank and Lines 310-01B-2 Fuel Filter 310-01B-5 REMOVAL AND INSTALLATION Fuel Cooler Fuel Tank Fuel Tank Fuel Tank Filler Pipe Fuel Tank Filler Pipe Fuel Filter Fuel Pump and Sender Unit Fuel Level Sender 310-01B-7 310-01B-8 310-01B-12 310-01B-15 310-01B-17 310-01B-19 310-01B-20 310-01B-22 Fuel Tank and Lines — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L 310-01B-2 Duratorq-TDCi (148kW/200PS) - Puma 310-01B-2 DESCRIPTION AND OPERATION Fuel Tank and Lines Vehicles with diesel engine Item Description Fuel filter Fuel tank 2011.50 Ranger G1274010en Fuel Tank and Lines — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L 310-01B-3 310-01B-3 Duratorq-TDCi (148kW/200PS) - Puma DESCRIPTION AND OPERATION Fuel tank supply and return lines Item Description Item Description Return line from fuel filter to fuel cooler Fuel tank Return line fuel cooler to fuel tank 10 Fuel tank breather hose Supply line fuel tank to fuel filter 11 Fuel tank vent valve breather Fuel level sensor locking ring 12 Filler neck Fuel level sensor/ fuel module 13 Fuel cooler Fuel tank vent valve(s) Tank protector Fuel tank support straps 2011.50 Ranger G1274010en Fuel Tank and Lines — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L 310-01B-4 310-01B-4 Duratorq-TDCi (148kW/200PS) - Puma DESCRIPTION AND OPERATION Fuel tank vent valves Fuel pump and sender unit Fuel tank ventilation is achieved by two fuel tank vent valves The fuel tank vent valves are integral to the fuel tank and will prevent fuel loss from the fuel tank if the vehicle becomes inverted Under normal working conditions, the pressure within the fuel tank is controlled by allowing the fuel vapor to vent through the fuel tank vent valves to atmosphere If the fuel tank becomes inverted, the fuel tank vent valves close preventing fuel being lost from the fuel tank If the fuel tank vent valves or the fuel vapor lines connected to the vent valves become restricted, vehicle performance will become impaired The inability of the fuel tank to substitute the fuel demanded by the fuel charging system with air, will create a negative pressure in the fuel tank which will result in reduced fuel flow to the fuel pump The fuel filler cap has both vacuum and pressure relief valves to prevent excess vacuum or pressure from causing deformation of the tank Item Description Fuel pump and sender unit locking ring Fuel pump and sender unit sealing ring Fuel level sensor resistor card Fuel jet pump Fuel pump inlet filter The pump and sender unit is located in the top of the fuel tank and is retained by a locking ring 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 central junction box (CJB) through a hard wired circuit The CJB distributes the information from the fuel level sensor to the instrument cluster and the powertrain control module (PCM) using the controller area network (CAN) circuits 2011.50 Ranger G1274010en Fuel Tank and Lines — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L 310-01B-5 310-01B-5 Duratorq-TDCi (148kW/200PS) - Puma DESCRIPTION AND OPERATION The fuel level sensor resistor card can be susceptible to contaminated fuel, which can affect electrical continuity and give false fuel level readings This condition is normally temporary and self-rectifying If the fuel level sensor 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 level sensor 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 DTC will be set in the CJB and the fuel gauge pointer will fall to its key-off position The base of the fuel pump and sender unit is a chamber that sits in the swirl bowl at the bottom of the fuel tank Built into the chamber is a filter element The fuel pump and sender unit 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 fuel supply tube Fuel tank The fuel tank is of plastic construction and is secured to the vehicle by two metal support straps, which are bolted to the ladder frame cross members The diesel fuel tank must contain at least litres of fuel before the fuel pump is operated Running the fuel pump with less than litres of fuel will cause damage to the fuel pump Fuel Filter Item Description Fuel filter Return line from engine to fuel filter Supply line from filter to engine Return line from filter to fuel tank Supply line from tank to fuel filter Water-in fuel sensor The diesel fuel filter separates air, water and other contaminants from fuel, in addition to retaining system backpressure The upper section of the filter incorporates the recirculation valve and the return valve The recirculation valve controls the flow of warm return fuel from the engine When fuel temperature drops below 20 C, the valve opens to direct return fuel to the filter, warming the fuel to prevent waxing When fuel temperature reaches 33 C, the valve closes and return fuel is directed back to the fuel tank via the fuel cooler The recirculation valve also has a small bypass that allows any build up of air from the recirculation of fuel to bleed out via the return line into the tank The return valve is positioned in the return circuit of the filter It controls the flow rate of the return fuel from the engine, and maintains the required backpressure at the fuel rail The lower section of the filter houses the filter element, water separator and the water-in-fuel level sensor 2011.50 Ranger G1274010en Fuel Tank and Lines — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L 310-01B-6 Duratorq-TDCi (148kW/200PS) - Puma 310-01B-6 DESCRIPTION AND OPERATION The water separator consists of two layers of foam that encourage the formation of water droplets to separate from the fuel Water accumulates at the bottom of the filter, which then lifts the water-in-fuel level sensor float The water-in-fuel indicator is triggered when 80 ml of water has accumulated in the filter Fuel filler Item Description Filler cap Fuel tank filler neck Fuel tank vent line Fuel tank filler hose Fuel tank breather hose The fuel tank filler neck incorporates a fuel tank breather hose The fuel tank breather hose is connected to the top of the fuel tank and exits just below the top of the fuel tank filler neck The fuel tank breather hose allows the displaced vapor above the fuel in the fuel tank to escape, avoiding fuel "spit back" and premature shut off during refueling The fuel filler cap seals to the fuel filler neck This is to prevent the escape of fuel vapor during normal operation and to prevent fuel loss in the event of a vehicle accident 2011.50 Ranger G1274010en Fuel Tank and Lines — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L 310-01B-7 Duratorq-TDCi (148kW/200PS) - Puma 310-01B-7 REMOVAL AND INSTALLATION Fuel Cooler 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) Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General Information, Description and Operation) Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures) Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation) Torque: 25 Nm Installation To install, reverse the removal procedure 2011.50 Ranger G1490983en Fuel Tank and Lines — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L 310-01B-8 Duratorq-TDCi (148kW/200PS) - Puma 310-01B-8 REMOVAL AND INSTALLATION Fuel Tank General Equipment Retaining Strap Transmission Jack Removal NOTE: Removal steps in this procedure may contain installation details Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, General Procedures) NOTE: Vehicles with load box WARNING: Make sure that the fuel pressure has dropped to zero and that the fuel temperature is at ambient air temperature Refer to: Fuel Tank Draining (310-00 Fuel System - General Information - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L 2011.50 Ranger Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General Information, Description and Operation) Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation) G1274011en Fuel Tank and Lines — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L 310-01B-9 Duratorq-TDCi (148kW/200PS) - Puma 310-01B-9 REMOVAL AND INSTALLATION NOTE: Make sure that the clamp is installed to the same orientation as when removed Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, General Procedures) 4x4 Torque: 15 Nm All vehicles CAUTION: Make sure that no strain is placed on the wiring harness NOTE: Slowly lower the fuel tank to access the fuel pump and sender unit electrical connector WARNING: Fuel may still be present in the fuel tank after draining General Equipment: Transmission Jack General Equipment: Retaining Strap Torque: 48 Nm Refer to: Quick Release Coupling (310-00 Fuel System - General Information - 2.2L 2011.50 Ranger G1274011en Fuel Tank and Lines — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L 310-01B-10 Duratorq-TDCi (148kW/200PS) - Puma 310-01B-10 REMOVAL AND INSTALLATION 10 2011.50 Ranger 11 General Equipment: Transmission Jack General Equipment: Retaining Strap G1274011en Fuel Tank and Lines — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L 310-01B-11 Duratorq-TDCi (148kW/200PS) - Puma 310-01B-11 REMOVAL AND INSTALLATION 12 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 13 Refer to: Quick Release Coupling (310-00 Fuel System - General Information - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, General Procedures) 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 2011.50 Ranger G1274011en Fuel Tank and Lines — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L 310-01B-12 Duratorq-TDCi (148kW/200PS) - Puma 310-01B-12 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 WARNING: Make sure that the fuel pressure has dropped to zero and that the fuel temperature is at ambient air temperature Refer to: Fuel Tank Draining (310-00 Fuel System - General Information - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, General Procedures) Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General Information, Description and Operation) Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation) Refer to: Quick Release Coupling (310-00 Fuel System - General Information - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, General Procedures) NOTE: Make sure that the clamp is installed to the same orientation as when removed 2011.50 Ranger G1520807en Fuel Tank and Lines — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L 310-01B-13 Duratorq-TDCi (148kW/200PS) - Puma 310-01B-13 REMOVAL AND INSTALLATION WARNING: Fuel may still be present in the fuel tank after draining Refer to: Quick Release Coupling (310-00 Fuel System - General Information - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, General Procedures) 4x4 10 Torque: 15 Nm All vehicles 11 General Equipment: Transmission Jack General Equipment: Retaining Strap Torque: 48 Nm 2011.50 Ranger G1520807en Fuel Tank and Lines — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L 310-01B-14 Duratorq-TDCi (148kW/200PS) - Puma 310-01B-14 REMOVAL AND INSTALLATION 12 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 13 Refer to: Quick Release Coupling (310-00 Fuel System - General Information - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, General Procedures) 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 2011.50 Ranger G1520807en Fuel Tank and Lines — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L 310-01B-15 Duratorq-TDCi (148kW/200PS) - Puma 310-01B-15 REMOVAL AND INSTALLATION Fuel Tank Filler Pipe Removal NOTE: Removal steps in this procedure may contain installation details Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation) NOTE: Vehicles with load box Remove the left-hand rear wheel and tire Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General Information, Description and Operation) Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation) NOTE: Make sure that the fuel tank is no more than 3/4 full 2011.50 Ranger G1274020en Fuel Tank and Lines — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L 310-01B-16 Duratorq-TDCi (148kW/200PS) - Puma 310-01B-16 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 - 2.2L Duratorq-TDCi (88kW/120PS) Puma/2.2L Duratorq-TDCi (96kW/130PS) Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) Puma, Removal and Installation) Installation To install, reverse the removal procedure 2011.50 Ranger G1274020en Fuel Tank and Lines — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L 310-01B-17 Duratorq-TDCi (148kW/200PS) - Puma 310-01B-17 REMOVAL AND INSTALLATION Fuel Tank Filler Pipe Removal NOTE: Removal steps in this procedure may contain installation details NOTE: Make sure that the clamp is installed to the same orientation as when removed NOTE: Vehicles with aluminium tray Torque: 11 Nm WARNINGS: Wait for a minimum of minute after the engine has stopped before carrying out any repair to the fuel system Make sure that the fuel tank is no more than 3/4 full Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General Information, Description and Operation) NOTE: Make sure that the clamp is installed to the same orientation as when removed 2011.50 Ranger G1519141en Fuel Tank and Lines — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L 310-01B-18 Duratorq-TDCi (148kW/200PS) - Puma 310-01B-18 REMOVAL AND INSTALLATION Installation To install, reverse the removal procedure 2011.50 Ranger G1519141en Fuel Tank and Lines — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L 310-01B-19 Duratorq-TDCi (148kW/200PS) - Puma 310-01B-19 REMOVAL AND INSTALLATION Fuel Filter Removal NOTE: Removal steps in this procedure may contain installation details Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General Information, Description and Operation) Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures) Refer to: Fuel Injection Component Cleaning (303-04 Fuel Charging and Controls - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, General Procedures) Installation To install, reverse the removal procedure 2011.50 Ranger G1274012en Fuel Tank and Lines — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L 310-01B-20 Duratorq-TDCi (148kW/200PS) - Puma 310-01B-20 REMOVAL AND INSTALLATION Fuel Pump and Sender Unit Special Tool(s) 310-127 Wrench, Fuel Tank Sender Unit Removal Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General Information, Description and Operation) NOTE: The O-ring seal is to be reused unless damaged Refer to: Fuel Tank (310-01 Fuel Tank and Lines - 2.2L Duratorq-TDCi (88kW/120PS) Puma/2.2L Duratorq-TDCi (96kW/130PS) Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) Puma, Removal and Installation) Refer to: Fuel Tank (310-01 Fuel Tank and Lines - 2.2L Duratorq-TDCi (88kW/120PS) Puma/2.2L Duratorq-TDCi (96kW/130PS) Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) Puma, Removal and Installation) CAUTION: Take extra care not to damage the fuel tank level sensor float and arm Special Tool(s): 310-127 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 2011.50 Ranger G1523931en