Fuel Selector Valve - Electric Ford Cab & Chassis Ranger

COMPONENT TESTING

Note. Specific component testing information not available. Refer to any tests performed during REMOVAL & INSTALLATION or OVERHAUL procedures

DESCRIPTION

System consists of main and auxiliary fuel tanks, tank selector valve, tank selector switch, fuel lines, and electrical wiring.

The system used in vehicles with 7.5L engines, consists of a fuel selector valve, fuel pump cut-off relay, tank selector relay, inertia switch, selector switch and an in-tank electric fuel pump.

OPERATION

The electrically-actuated fuel selector valve is spring- loaded. In de-energized state, fuel pump is fed from rear tank. When activated by battery voltage through selector switch, fuel feed transfers from rear to front tank.

An electrically-actuated, 6-port, fuel selector valve is used in vehicles equipped with 2.3L Turbo Diesel, 6.9L Diesel and 7.5L engines.

Vehicles with Diesel Engines

1. Turn key to "RUN" position. Place switch in "FRONT" position. Disconnect selector valve connector. Check voltage between terminals 2 and 1. If okay, go to step 2. If no voltage is present, go to step 3.
2. Using a jumper wire, connect motor terminal 2 to battery positive post. Using a second jumper wire, connect motor terminal 1 to ground. Motor should run. Reverse jumper wires, motor should run in opposite direction. If motor does not run in one or both directions, replace motor. If motor runs in both directions, go to step 4.
3. Check voltage across fuse No.7 (No. 15 on 6.9L engines) in fuse block. If fuse is blown, repair shorts in selector valve circuit. Replace fuse, repeat test starting at step 1. If fuse is okay, check voltage between terminal 2 and ground. If okay, check for open ground circuit from motor, through switch to ground. If ground circuit is not okay, repair ground circuit. If ground circuit is okay, go to step 4.
4. Remove the selector valve switch knob and trim bezel. Remove switch mounting screws and disconnect switch from harness connector. With switch in "FRONT" position, check continuity between terminals 2 and 4, and between terminals 1 and 3. Place switch in "REAR" position, check continuity between terminals 1 and 4, and between terminals 2 and 3.
5. If continuity is not okay, replace selector valve switch. If continuity is okay, check continuity of Orange wire (circuit 974) and Brown/White wire (circuit 674) between selector switch and selector valve. If continuity is not okay, repair open circuits. If continuity is okay, go to step 6.
6. On 2.3L Turbo Diesel engine, turn key to "RUN" position. Place switch in "FRONT" position and turn key off. Pinch off fuel line from rear tank to selector valve. Remove fuel hose between fuel filter and injection pump, place end of fuel line into a container.
7. Operate primer pump on fuel filter header to obtain a minimum of 1 pint of fuel. Check for solid, continuous flow of fuel. If fuel flow is not okay, go to step 10. If fuel flow is okay, remove clamping tool and go to step 12.
8. On 6.9L engine, turn key to "RUN" position. Place switch in "FRONT" position and turn key off. Pinch off fuel line from rear tank at selector valve. Remove vacuum purge valve from fuel filter adapter. Install Adapter (3019) from Rotunda Pressure Test Kit (190002).
9. Start engine and let idle. Open clamp on sample hose, allowing fuel to flow into a container. Check for solid, continuous flow of fuel. If fuel flow is not okay, go to step 10. If fuel flow is okay, remove clamping tool and go to step 13.
10. Disconnect supply hose to engine at selector valve. Disconnect supply hose from front tank at selector valve. Connect two hoses together using a piece of fuel line. On 2.3L Turbo Diesel engines, repeat steps 6 and 7. On 6.9L engines, repeat steps 8 and 9. If fuel flow is okay (either engine), replace fuel selector valve.
11. If fuel flow is not okay (either engine), check front fuel tank sender, sedimentor, fuel filter and fuel lines for restrictions. If restrictions are found, clean, repair or replace components as necessary. If components are okay, check fuel level. On 2.3L Turbo Diesel engine, repeat steps 6 and 7. On 6.9L engine, repeat steps 8 and 9.
12. On 2.3L Turbo Diesel engine, turn key to "RUN" position. Place selector valve in "REAR" position and turn key off. Pinch off fuel line between front tank and selector valve. Operate primer pump on fuel filter header to obtain a minimum of 1 pint of fuel. Check for solid, continuous flow of fuel.
13. On 6.9L engine, turn key to "RUN" position. Place switch in "REAR" position and turn key off. Pinch off fuel line between front tank and selector valve. Remove vacuum purge valve from fuel filter adapter. Install Adapter (3019) from Rotunda Pressure Test Kit (19 0002). Start engine and let idle. Open clamp on sample hose, allowing fuel to flow into container. Check for a solid, continuous fuel flow.
14. If fuel flow is not okay (either engine), go to step 15. If fuel flow is okay (either engine), fuel supply system is okay. Connect fuel line to fuel injection pump. Remove clamping tool from front tank supply line and go to step 17.
15. Disconnect supply hose to engine at selector valve. Disconnect supply hose from rear tank at selector valve. Connect two hoses together using a piece of fuel line. On 2.3L Turbo Diesel engine, repeat steps 6 and 7. On 6.9L engine, repeat steps 8 and 9. On all vehicles, if fuel flow is okay, replace selector valve.
16. If fuel flow is not okay, check rear fuel tank sender and fuel lines to selector valve for restrictions. If restrictions are found, clean, repair or replace components and repeat step 15. If components are okay, check fuel tank fuel level and repeat step 15.
17. Disconnect fuel return hose from engine at selector valve and insert line into a container. Turn key to "RUN" position and place switch in "FRONT" or "REAR" position (problem tank). Start engine and check for a solid, continuous flow of fuel.
18. If fuel flow is okay, turn engine off. Connect fuel return line to selector valve and go to step 19. If fuel flow is not okay, check return line for restrictions. If restrictions are found, repair or replace as necessary and repeat step 17.
19. Disconnect fuel return line to problem tank at selector valve. Attach a 5/16" diameter hose to selector valve return port and insert end of hose into container. Start engine and check for a solid, continuous flow of fuel.
20. If fuel flow is okay, check fuel sender and fuel line to tank (front or rear) for restrictions. If restrictions are found, repair or replace as necessary. Run engine and check for smooth running. If fuel flow is not okay, replace fuel selector valve.

Ford Six-Port Fuel Selector Valve Terminals are not numbered on valve. Scheme 33

7.5L Engine

1. Turn key to "RUN" position. Place switch in "FRONT" position. Disconnect selector valve connector. Check for voltage between connector terminal 2 and ground. If voltage is present, go to step 3.
2. If no voltage is present, check voltage across fuse at fuse block. If fuse is blown, check selector valve circuit for shorts. Repair shorts, replace fuse and repeat step 1. If fuse is okay, go to step 6.
3. Check for voltage between selector valve connector terminals 2 and 1. If voltage is present, go to step 4. If no voltage is present, check for open ground circuit from valve connector, through selector switch to ground. If circuit is okay, go to step 6. If not okay, repair ground circuit, repeat test.
4. Place switch in "REAR" position, and check for voltage between connector terminal 1 and ground. If voltage is present, go to step 5. If no voltage is present, go to step 6.
5. Check for voltage between selector valve connector terminal 1 and 2. If voltage is present, go to step 8. If no voltage is present, check for open ground circuit from valve connector, through selector switch to ground. If circuit is okay, go to step 6. If not okay, repair ground circuit, repeat step 3.
6. Remove selector switch from instrument panel. Disconnect switch from harness. With switch in "FRONT" position, check for continuity between terminals 2 and 4, and between terminals 1 and 3.
7. Place switch in "REAR" position and check for continuity between terminal 1 and 4, and between terminals 2 and 3. If switch is okay, go to step 10. If switch is not okay, replace switch. NOTE: Selector valve will make a "zip" sound when shifting from one mode to another.
8. Using a jumper wire, connect selector valve terminal 2 to battery positive post. Using a second jumper wire, connect terminal 1 to ground. If valve is in "FRONT" mode, nothing will occur. Reverse jumper wires, valve should shift to "REAR" mode.
9. Reverse jumper wires once more, valve should shift to "FRONT" mode. If valve shifts into both modes, go to step 12. If valve does not shift into both modes, replace fuel selector valve.
10. On E series, check continuity of Brown/Orange wire (circuit 808) and Red/Yellow wire (circuit 739) between selector switch and selector valve. On F series, check continuity of Brown/ White wire (circuit 674) and Orange wire (circuit 974) between selector switch and selector valve.
11. If continuity between selector switch and selector valve is okay, go to step 12. If continuity between selector switch and selector valve is not okay, repair open circuits as necessary.
12. Remove connector from oil pressure switch and insert temporary shorting wire between two connector terminals. Pinch off fuel line between rear tank and selector valve. Remove fuel hose to carburetor, and place end of fuel hose into a container. NOTE: Fuel pump volume is approximately 1/2 gallon/minute.
13. Turn key to "RUN" position. Place switch in "FRONT" position. Check for a solid, continuous fuel flow. If fuel flow is not okay, go to step 14. If fuel flow is okay, remove clamping tool from rear supply line, go to step 18.
14. Disconnect supply hose to engine at selector valve. Disconnect supply hose from front tank at selector valve. Connect two hoses together using a length of fuel line. Repeat steps 12 and 13. If fuel flow is okay, replace fuel selector valve.
15. If fuel flow is not okay, check front fuel tank sender, fuel lines and fuel filter for restrictions. If restrictions are found, clean, repair or replace components as necessary and repeat steps 12 and 13.
16. If lines, filter and sender are okay, remove front fuel tank sender connector. Connect a 12-volt test lamp to pump terminal and to ground terminal of sender connector.
17. With key in "RUN" position and with switch in "FRONT" position, test lamp should light continuously and should go out as soon as rear tank is selected. Check fuel pump. If fuel pump is okay, continue test.
18. Remove connector from oil pressure switch and insert temporary shorting wire between two connector terminals. Pinch off fuel line between front tank and selector valve. Remove fuel hose to carburetor, and place end of fuel hose into a container.
19. Turn key to "RUN" position and place switch in "REAR" position. Check for a solid, continuous flow of fuel. If fuel flow is not okay, go to step 20. If fuel flow is okay, selector valve is operating properly.
20. Disconnect supply hose to engine at selector valve. Disconnect supply hose from rear tank at selector valve. Connect two hoses together using a length of fuel line. Repeat steps 18 and 19.
21. If fuel flow is okay, replace fuel selector valve. If fuel flow is not okay, remove rear fuel tank sender connector. Connect a 12-volt test lamp to pump terminal and to ground terminal of sender connector.
22. With key in "RUN" position and with switch in "REAR" position, test lamp should light continuously and should go out as soon as front tank is selected. Check fuel pump. If fuel pump is okay, fuel supply system is okay.

All Other Models

1. Turn ignition to "RUN" and place switch in "FRONT" position. Disconnect fuel selector valve. Using a 12-volt test lamp, check for voltage between wire harness terminal and ground. If test lamp comes on, go to step 3. If lamp does not come on, check fuse at fuse block.
2. If fuse is blown, check fuel valve circuit and valve for short. Repair as necessary and replace fuse. If fuse is okay, check switch for continuity in auxiliary tank position. If no continuity, replace switch. If switch is okay, check wiring and valve for open circuit and repair as necessary.
3. Reconnect valve wire and place a paper clip on bottom end of valve. Paper clip should adhere to valve. If paper clip adheres, go to step 5. If paper clip does not adhere, ground valve case to frame rail with a jumper wire, and repeat paper clip test.
4. If paper clip still does not adhere, replace valve and solenoid assembly. If paper clip adheres, remove valve mounting bolts, and clean mounting surface. Install valve using zinc or cadmium plated bolts and washers.
5. Position switch in "MAIN" position and pinch off fuel hose from valve to main tank. Remove fuel line from carburetor, and place end of fuel line into a container. Remove battery feed from coil, and crank engine. Check fuel flow.
6. If fuel flows continuously, remove and replace valve solenoid assembly. If no fuel flows into container, check for plugged fuel line. If fuel lines are okay, fuel selector valve is operating correctly.

Disconnect fuel hoses from selector valve. Remove electrical connections. Remove nut and ground wire. Remove valve attaching bolts, and remove valve. To install, reverse removal procedure. Ensure ground wire is securely fastened. Because solenoid is internally grounded, specified mounting bolts must be used.

SPECIFICATIONS

Note. Specifications table not available. Refer to specifications within appropriate TESTING subject(s) in this article.

WIRING DIAGRAMS

Note. For complete system wiring diagrams, see the appropriate WIRING DIAGRAMS article in the WIRING DIAGRAMS section.

Selector Valve Wiring Harness. Scheme 34

See also:
• TESTING