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Fuel System-General Information Ford Cutaway E350

Fuel System 21 illustrations ~824 words

GENERAL SPECIFICATIONS

ItemSpecification
Fuel Tank Capacity
E-150, E-250, E-350 Van/Wagon Midship132 L (35 gal) standard
E-350 Commercial Chassis aft-of-axle140 L (37 gal) standard 208 L (55 gal) optional
E-450 Commercial Chassis aft-of-axle208 L (55 gal) standard
Fuel PressureFUEL SYSTEM SPECIFICATIONS
Lubricant
SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP or equivalentWSS-M2C930-A

GENERAL SPECIFICATIONS

Scheme 105

Scheme 105: Fuel System - 4.6L, 5.4L and 6.8L
Scheme 105: Fuel System - 4.6L, 5.4L and 6.8L
WARNINGFuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.

The vehicle

  1. is equipped with a multiport fuel injection (MFI) system.
  2. has separately controlled fuel injectors mounted to the intake manifold for each cylinder.
  3. has fuel injectors which are supplied with pressurized fuel from the fuel pump through the fuel rail.
  4. has a fuel rail which is equipped with a fuel rail pressure (FRP) sensor.

Scheme 106

Scheme 106: Fuel System - 6.0L Diesel
Scheme 106: Fuel System - 6.0L Diesel

The fuel system for the direct injection turbo (DIT) diesel

  1. is controlled by the powertrain control module (PCM).
  2. utilizes an electric, frame mounted fuel pump.
  3. incorporates a fuel filter and water separator assembly.

The electric fuel pump

  1. draws fuel from the tank.
  2. circulates fuel under pressure through the fuel filter, the water separator, and the pressure regulator to the cylinder head fuel galleries and then to the fuel injectors.
  3. Excess fuel is returned to the fuel tank through the fuel return hose.

Fuel Filter/Water Separator

The diesel engine is equipped with a fuel filter and water separator assembly. Drain the water from the fuel filter at the recommended maintenance intervals. Refer to the appropriate article for maintenance intervals. If there is water in the fuel an indicator on the instrument panel will alert the operator. When the indicator glows continuously while the engine is running, drain the water from the fuel filter and water separator bowl as soon as possible to prevent damage to the fuel injection system.

Fuel System Pressure Release - Gasoline Engines

WARNINGDo not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and can be ignited, resulting in possible personal injury.
WARNINGFuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.
  1. Remove the fuel pump fuse from the engine compartment fuse box.
  2. Start the engine and allow it to idle until it stalls.
  3. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel injection supply manifold pressure has been relieved.
  4. Turn the ignition switch to the OFF position.
  5. When fuel system service is complete, install the fuel pump fuse.
  6. Cycle the ignition key and wait three seconds to pressurize the fuel system. Check for leaks before starting the engine.
  7. Start the vehicle and check the fuel system for leaks.

Fuel System Pressure Release - Diesel Engines

WARNINGDo not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury.
WARNINGFuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.

Scheme 107

Scheme 107
Scheme 107
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
  2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
  3. Open the fuel/water separator drain valve to release the fuel pressure.

Special Tool(s)

SPECIAL TOOL 30 Gallon Gasoline Hand Pump Storage Tanker 164-R3201 or equivalent

Scheme 108

Scheme 108: Special Tool(s)
Scheme 108: Special Tool(s)

Draining

WARNINGDo not smoke, carry lighted tobacco or an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury.

Scheme 109

Scheme 109
Scheme 109

Scheme 110

Scheme 110
Scheme 110
  1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
  2. Disconnect the fuel vent tube.
  3. Remove the rear vapor valve from the fuel tank.
  4. Insert the hose from the storage tank and remove the fuel.

SPECIAL TOOL Fuel Line Removal Tool 310-S039 (T90T-9550-S)

Scheme 111

Scheme 111: Special Tool(s)
Scheme 111: Special Tool(s)

Material

ItemSpecification
SAE 5W-20 Premium Synthetic Blend Engine Oil XO-5W20-QSP or equivalentWSS-M2C930-A

MATERIAL SPECIFICATION

Disconnect

WARNINGDo not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and can be ignited, resulting in possible personal injury.
WARNINGFuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.

Scheme 112

Scheme 112
Scheme 112

Scheme 113

Scheme 113
Scheme 113

Scheme 114

Scheme 114
Scheme 114
  1. Release the fuel pressure. For additional information, refer to «FUEL SYSTEM PRESSURE RELEASE - GASOLINE ENGINES»(/ford/cutaway-e350/2004-2007/remont/fuel-system/#fuel-system-general-information__fuel-system-pressure-release-gasoline) or «FUEL SYSTEM PRESSURE RELEASE - DIESEL ENGINES»(/ford/cutaway-e350/2004-2007/remont/fuel-system/#fuel-system-general-information__fuel-system-pressure-release-diesel) .
  2. Disconnect the safety clip from the male hose.
  3. Install the fuel tube disconnect tool and push into the fitting.
  4. Separate the fittings. Inspect for damage. Clean the fittings.

Scheme 115

Scheme 115: Connect
Scheme 115: Connect
  1. Align and push the tube into the fitting until you hear a click.
  2. Pull on the fitting to make sure it is fully engaged, then install safety clip.

SPECIAL TOOLS Disconnect Tool (3/8-Inch) 310-D004 (D87L-9280-A) or equivalent Disconnect Tool (1/2-Inch) 310-D005 (D87L-9280-B) or equivalent

Scheme 116

Scheme 116: Special Tool(s)
Scheme 116: Special Tool(s)

Scheme 117

Scheme 117
Scheme 117
ItemSpecification
SAE 5W-20 Premium Synthetic Blend Engine Oil XO-5W20-QSP or equivalentWSS-M2C930-A

MATERIAL SPECIFICATION

WARNINGDo not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and can be ignited, resulting in possible personal injury.
WARNINGFuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.

Scheme 118

Scheme 118
Scheme 118

Scheme 119

Scheme 119
Scheme 119

Scheme 120

Scheme 120
Scheme 120

Scheme 121

Scheme 121
Scheme 121

Scheme 122

Scheme 122
Scheme 122
  1. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM PRESSURE RELEASE - GASOLINE ENGINES»(/ford/cutaway-e350/2004-2007/remont/fuel-system/#fuel-system-general-information__fuel-system-pressure-release-gasoline) or «FUEL SYSTEM PRESSURE RELEASE - DIESEL ENGINES»(/ford/cutaway-e350/2004-2007/remont/fuel-system/#fuel-system-general-information__fuel-system-pressure-release-diesel) .
  2. Remove the fuel tube clip.
  3. Install the disconnect tool.
  4. Close and push the disconnect tool into the open side of the cage.
  5. Separate the fitting.
  6. Remove the disconnect tool.

Scheme 123

Scheme 123: Connect
Scheme 123: Connect
  1. Connect the fitting. Inspect and clean both the coupling ends. Lubricate the O-rings with clean engine oil. Connect the fitting. Pull on the fitting to make sure it is fully engaged. Install the safety clip.
ItemSpecification
SAE 5W-20 Premium Synthetic Blend Engine Oil XO-5W20-QSP or equivalentWSS-M2C930-A

MATERIAL SPECIFICATION

WARNINGDo not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present an may be ignited, resulting in possible personal injury.
WARNINGFuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel tubes or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.
WARNINGThe evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery ground cable from the battery to minimize the possibility of an electrical spark occurring, possibly causing a fire or explosion if fuel vapor or liquid fuel are present in the area. Failure to follow these instructions may result in personal injury.
CAUTIONDo not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks.

Scheme 124

Scheme 124
Scheme 124
  1. Release the fuel system pressure, if necessary. For additional information, refer to «FUEL SYSTEM PRESSURE RELEASE - GASOLINE ENGINES»(/ford/cutaway-e350/2004-2007/remont/fuel-system/#fuel-system-general-information__fuel-system-pressure-release-gasoline) or «FUEL SYSTEM PRESSURE RELEASE - DIESEL ENGINES»(/ford/cutaway-e350/2004-2007/remont/fuel-system/#fuel-system-general-information__fuel-system-pressure-release-diesel) .
  2. Depress the locking ring to release the tube from the coupling.

Scheme 125

Scheme 125: Connect
Scheme 125: Connect
  1. Inspect the fitting and the tube for damage. Remove any dirt or obstructions.
  2. Apply a light coat of clean engine oil to the male tube end.
  3. Insert the tube into the coupling and push them together until a click is heard.
  4. Pull on the connection to make sure it is fully engaged.

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