Fuel System - General Information Ford Econoline E250

SPECIFICATIONS

MATERIAL SPECIFICATIONS

GENERAL SPECIFICATIONS

The fuel system consists of the following components

1. Fuel and vapor tubes
2. Fuel Pump (FP) module (located in the fuel tank)
3. Fuel tank filler pipe assembly
4. Fuel tank
5. Fuel rail (located on the engine)
6. Fuel injectors (located on the fuel rail)

The vehicle is equipped with a Multi-Port Fuel Injection (MFI) system. The fuel injectors are separately controlled and are mounted to the intake manifold. The fuel injectors are supplied with pressurized fuel from the FP module through the fuel rail. The 2 speed Mechanical Returnless Fuel System (MRFS) controls the FP module through the PCM. The fuel rail has a fuel pressure sensor which controls the pressure going to the fuel injectors. The fuel system is a 2-speed MRFS. The fuel system has a Fuel Pump Control Module (FPCM), which varies voltage to the FP based on fuel system demand.

Fuel Pump (FP) Shut-off Feature

In the event of a moderate to severe collision, the vehicle is equipped with a Fuel Pump (FP) shut-off feature that is initiated by the event notification signal.

The event notification signal is a signal provided by the Restraints Control Module (RCM) to the FPCM. Signal communication between the RCM and the FPCM allows the PCM to shut-off the FP.

Should the vehicle shut off after a collision due to this feature, the vehicle may be restarted by first turning the ignition switch to the OFF position and then turn the ignition switch to the ON position. In some instances the vehicle may not start the first time and may take one additional key cycle.

For exploded view information of the fuel system, refer to Fuel Tank and Filler Pipe - Exploded View or Fuel Line in FUEL TANK AND LINES .

SPECIAL TOOLS CHART Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

Scheme 1

MATERIAL SPECIFICATIONS

Principles of Operation

Note. The following procedure diagnoses a slow-to-fill concern only. For all other concerns, refer to the INTRODUCTION - GASOLINE MODELS .

The fuel tank filler pipe assembly is used to refuel the vehicle. The fuel tank inlet check valve prevents spitback of fuel during and after refueling. The fuel tank stores the fuel. The fuel tank contains a Fuel Pump (FP) module. The FP module consists of a fuel level sensor, FP and a lifetime fuel filter. The fuel level sensor sends a signal to the fuel gauge informing the driver of how much fuel is in the fuel tank. The FP provides fuel to the fuel tubes which supply the fuel rail.

During refueling, the fuel tank vents to the atmosphere through the vent and filler pipes on vehicles without On-Board Refueling Vapor Recovery (ORVR) systems. In vehicles equipped with ORVR, the fuel tank and filler pipe are designed so that when the vehicle is being refueled, fuel vapors in the fuel tank travel to the Evaporative Emission (EVAP) canister, which absorbs the fuel vapors and vents the pressure from the fuel tank during refueling.

Inspection and Verification

Note. Do not use incandescent lights when inspecting the fuel system. Use only flourescent or LED lighting.

1. Verify the customer concern by refueling the vehicle and observe the fuel fill rate.
2. Inspect to determine if any of the following mechanical concerns apply. VISUAL INSPECTION CHART Mechanical Bent, kinked or damaged fuel tank filler pipe Bent, kinked or damaged fuel tank filler pipe vent tube (if equipped) Incorrect routing of the fuel tank filler pipe Incorrect routing of the fuel tank filler pipe vent tube (if equipped) Incorrect position of fuel tank filler pipe clamps Incorrect position of fuel tank filler pipe vent tube clamps (if equipped) Fuel tank mounted vapor tubes bent or damaged Evaporative Emission (EVAP) system tubes or hoses bent or damaged Accident damage to the fuel tank Accident damage to the vehicle effecting the fuel tank filler pipe-to-body connection Unauthorized modifications and/or alterations to the vehicle EVAP system fresh air tube plugged (dirt, spider webbing)
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
4. If the cause is not visually evident, connect the scan tool to the Data Link Connector (DLC).
5. If the scan tool does not communicate with the VCM: check the VCM connection to the vehicle. check the scan tool connection to the VCM. refer to «MODULE COMMUNICATIONS NETWORK»(/ford/econoline-e250/2012-2013/remont/communication-devices/#module-communications-network) , No Power To The Scan Tool, to diagnose no power to the scan tool.
6. If the scan tool does not communicate with the vehicle: verify the ignition key is in the ON position. verify the scan tool operation with a known good vehicle. refer to «MODULE COMMUNICATIONS NETWORK»(/ford/econoline-e250/2012-2013/remont/communication-devices/#module-communications-network) to diagnose no response from the PCM.
7. Carry out the network test. If the scan tool responds with no communication for one or more modules, refer to «MODULE COMMUNICATIONS NETWORK»(/ford/econoline-e250/2012-2013/remont/communication-devices/#module-communications-network) . If the network test passes, retrieve and record continuous memory DTCs.
8. Clear the continuous DTCs and carry out the self-test diagnostics for the EVAP system.
9. If the DTCs retrieved are related to the concern, go to «EVAPORATIVE EMISSION SYSTEM DTC CHART»(/ford/econoline-e250/2012-2013/remont/fuel-system/#fuel-system-general-information__evaporative-emission-system-dtc-table) . For PCM related DTCs, refer to the «INTRODUCTION - GASOLINE MODELS»(/ford/econoline-e250/2012-2013/remont/oem-general-information/#service-information-introduction) . For all other DTCs, refer to «MULTIFUNCTION ELECTRONIC MODULES»(/ford/econoline-e250/2012-2013/remont/cruise-control-systems/#multifunction-electronic-modules) .
10. If no DTCs related to the concern are retrieved, GO to «SYMPTOM CHART»(/ford/econoline-e250/2012-2013/remont/fuel-system/#fuel-system-general-information__symptom-chart) .

Evaporative Emission System DTC Table

EVAPORATIVE EMISSION SYSTEM DTC TABLE

Symptom Chart

SYMPTOM CHART

Normal Operation

Under normal operation, fuel should flow at a steady rate through the fuel tank filler pipe into the fuel tank. As fuel enters the fuel tank, air is vented through the filler pipe or the On-Board Refueling Vapor Recovery (ORVR) system.

This pinpoint test is intended to diagnose the following

1. Fuel tank filler pipe vent tube, if equipped
2. Fuel tank filler pipe
3. Evaporative Emission (EVAP) system
4. Fuel tank inlet check valve (part of the fuel tank)
5. Fuel level vent valve, if equipped (part of the Fuel Pump (FP) module)

PINPOINT TEST A: SLOW TO FILL

1. A1 CARRY OUT INSPECTION AND VERIFICATION Carry out «INSPECTION AND VERIFICATION»(/ford/econoline-e250/2012-2013/remont/fuel-system/#fuel-system-general-information__inspection-and-verification) . Was the cause of the concern found? Yes : REPAIR or INSTALL new components to correct the concern. No : GO to A2.
2. A2 CHECK THE SYSTEM FOR ANY EVAP DTCs Connect the scan tool. Check the system for any of the following EVAP DTCs: P0446, P0451, P0452, P0453, P0454, P1450, P1451 and P260F. Are any of these DTCs present? Yes : REFER to «INTRODUCTION - GASOLINE MODELS»(/ford/econoline-e250/2012-2013/remont/oem-general-information/#service-information-introduction) to diagnosis the EVAP system. No : GO to A3.
3. A3 MONITOR THE FTP WHILE FILLING THE FUEL TANK Monitor the Fuel Tank Pressure (FTP) reference value while filling the fuel tank. Refer to the Reference Values in the «INTRODUCTION - GASOLINE MODELS»(/ford/econoline-e250/2012-2013/remont/oem-general-information/#service-information-introduction) . Is FTP within specification? Yes : GO to A5 . No : GO to A4.
4. A4 MONITOR THE FTP WHILE FILLING THE FUEL TANK WITH THE EVAP SYSTEM DISCONNECTED Disconnect the fuel tank-to-EVAP canister quick connect coupling at the EVAP canister. Monitor the FTP reference value while filling the fuel tank. Refer to «INTRODUCTION - GASOLINE MODELS»(/ford/econoline-e250/2012-2013/remont/oem-general-information/#service-information-introduction) . Is FTP within specification? Yes : INSPECT the EVAP system for blockage or restrictions. REPAIR the blockage or restriction. If the blockage or restriction cannot be repaired, INSTALL new EVAP system components. No : GO to A5.
5. A5 CHECK THE FUEL TANK FILLER PIPE ASSEMBLY FOR BLOCKAGE OR RESTRICTION Remove the fuel tank filler pipe assembly. Refer to «FUEL TANK AND LINES»(/ford/econoline-e250/2012-2013/remont/fuel-system/#fuel-tank-fuel-lines) . Inspect the fuel tank filler pipe and fuel tank filler pipe vent tube (if equipped) for a blockage or restriction. Is the fuel tank filler pipe or fuel tank filler pipe vent tube (if equipped) blocked or restricted? Yes : If possible, REPAIR the blockage or restriction. If the blockage or restriction cannot be repaired, INSTALL a new fuel tank filler pipe or fuel tank filler pipe vent tube. No : GO to A6.
6. A6 CHECK THE FUEL TANK INLET CHECK VALVE Inspect the fuel tank inlet check valve for restriction or sticking. Is the fuel tank inlet check valve restricted or sticking? Yes : If possible, REPAIR the restriction. If the restriction cannot be repaired, INSTALL a new fuel tank inlet check valve. Lubricate the O-ring seal with clean motor oil prior to installation. No : GO to A7.
7. A7 CHECK TO MAKE SURE THAT THE FUEL LEVEL VENT VALVE IS FUNCTIONING CORRECTLY NOTE: The fuel level vent valve, if equipped, is part of the FP module. Remove the FP module. Refer to «FUEL TANK AND LINES»(/ford/econoline-e250/2012-2013/remont/fuel-system/#fuel-tank-fuel-lines) . Inspect the fuel level vent valve for foreign material at the bottom drain hole. Invert the FP module. Watch for a movement and a click noise. Was a movement/click noise witnessed? Yes : Fuel level vent valve is OK. RETEST the system for normal operation. No : INSTALL a new FP module. REFER to «FUEL TANK AND LINES»(/ford/econoline-e250/2012-2013/remont/fuel-system/#fuel-tank-fuel-lines) .

Fuel System Pressure Release

SPECIAL TOOLS CHART Fuel Pressure Test Kit 310-D009 (D95L-7211-A) or equivalent

Scheme 2

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/econoline-e250/2012-2013/remont/charging-system/#battery-battery-mounting-battery-cables) .
2. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/econoline-e250/2012-2013/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
3. Remove the cap from the fuel pressure relief valve located on the fuel rail.
4. Install the Fuel Pressure Test Kit onto the fuel pressure relief valve.
5. Open the manual valve on the Fuel Pressure Test Kit and relive the fuel pressure.
6. Once fuel system service is complete, install the cap on the fuel pressure relief valve.
7. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/econoline-e250/2012-2013/remont/charging-system/#battery-battery-mounting-battery-cables) .
8. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine.
9. Start the vehicle and check the fuel system for leaks.

Fuel System Pressure Test

SPECIAL TOOLS CHART Fuel Pressure Test Kit 310-D009 (D95L-7211-A) or equivalent

1. Remove the cap from the fuel pressure relief valve located on the fuel rail.
2. Install the Fuel Pressure Test Kit onto the fuel pressure relief valve.
3. Test the fuel system pressure to make sure it is within the specified range. For additional information, refer to «SPECIFICATIONS»(/ford/econoline-e250/2012-2013/remont/fuel-system/#fuel-system-general-information__specifications) .
4. Upon completion of the fuel system pressure test, open the drain valve on the Fuel Pressure Test Kit and relieve the fuel system pressure.
5. Install the cap on the fuel pressure relief valve.
6. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine.

Fuel Tank Draining

SPECIAL TOOLS CHART 100 Gallon Manual Fuel Tanker 292-00004 or equivalent

Scheme 3

MATERIAL SPECIFICATIONS

Note. Midship fuel tank shown in illustration, aft-of-axle tank similar.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/econoline-e250/2012-2013/remont/hoistjack/#jacking-lifting) .
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM PRESSURE RELEASE»(/ford/econoline-e250/2012-2013/remont/fuel-system/#fuel-system-general-information__fuel-system-pressure-release) .
3. If connected, disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/econoline-e250/2012-2013/remont/charging-system/#battery-battery-mounting-battery-cables) .
4. Release the fuel tank filler cap and position aside.
5. Insert a suitable fuel drain tube into the fuel tank filler pipe until it stops.
6. Attach the 100 Gallon Manual Fuel Tanker to the fuel drain tube and remove as much fuel as possible from the fuel tank filler pipe.
7. Remove the fuel tank filler pipe hose at the fuel tank-to-fuel tank filler pipe hose connection. Loosen the clamp and disconnect the fuel tank filler pipe hose.
8. Insert the hose from the 100 Gallon Manual Fuel Tanker and siphon the fuel through the fuel tank filler pipe opening in the fuel tank.

Quick Connect Coupling

MATERIAL SPECIFICATIONS

Disconnect

Note. Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is essential that absolute cleanliness is observed when working with these components or component damage may occur. Always install plugs to any open orifices or tubes.

Note. When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube or damage to the tube or connector retaining clip may occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector.

Note. During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor openings must be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials must be removed prior to installation.

Scheme 4

1. If servicing a liquid fuel tube, release the fuel system pressure. For additional information, refer to «FUEL SYSTEM PRESSURE RELEASE»(/ford/econoline-e250/2012-2013/remont/fuel-system/#fuel-system-general-information__fuel-system-pressure-release) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/econoline-e250/2012-2013/remont/charging-system/#battery-battery-mounting-battery-cables) .
3. Disconnect the fuel tube quick connect coupling. Press the fuel tube quick connect coupling button and pull the fuel tube to disconnect.

Connect

1. Inspect the quick connect coupling and the tube for damage. Remove any dirt or obstructions.
2. Install the quick connect coupling onto the tube until it is fully seated.
3. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/econoline-e250/2012-2013/remont/charging-system/#battery-battery-mounting-battery-cables) .

Disconnect - Type II

Note. Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is essential that absolute cleanliness is observed when working with these components or component damage may occur. Always install plugs to any open orifices or tubes.

Note. When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube or damage to the tube or connector retaining clip may occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector.

Note. During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor openings must be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials must be removed prior to installation.

Scheme 5

1. If servicing a liquid fuel tube, release the fuel system pressure. For additional information, refer to «FUEL SYSTEM PRESSURE RELEASE»(/ford/econoline-e250/2012-2013/remont/fuel-system/#fuel-system-general-information__fuel-system-pressure-release) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/econoline-e250/2012-2013/remont/charging-system/#battery-battery-mounting-battery-cables) .
3. Spread the legs of the retainer clip and pull it to the outward position in the quick connect coupling.
4. Depress the retainer clip and disconnect the quick connect coupling from the tube.

Connect - Type II

1. Inspect the quick connect coupling and the tube for damage. Remove any dirt or obstructions.
2. Install the quick connect coupling onto the tube until fully seated.
3. Press the retainer clip into the quick connect coupling body until flush and the legs are locked in place.
4. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/econoline-e250/2012-2013/remont/charging-system/#battery-battery-mounting-battery-cables) .

Disconnect - Type III

Note. When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube or damage to the tube or connector retaining clip may occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector.

Note. During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor openings must be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials must be removed prior to installation.

Scheme 6

1. Release the locking tab on the quick connect coupling.
2. Separate the quick connect coupling from the fitting.

Connect - Type III

1. Inspect the quick connect coupling and the tube for damage. Remove any dirt or obstructions.
2. Release the locking tab and install the quick connect coupling onto the fitting.
3. Position the locking tab into the latched position.

Disconnect - Type IV

Note. Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is essential that absolute cleanliness is observed when working with these components or component damage may occur. Always install plugs to any open orifices or tubes.

Note. When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube or damage to the tube or connector retaining clip may occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector.

Note. During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor openings must be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials must be removed prior to installation.

Scheme 7

Scheme 8

1. If servicing a liquid fuel tube, release the fuel system pressure. For additional information, refer to «FUEL SYSTEM PRESSURE RELEASE»(/ford/econoline-e250/2012-2013/remont/fuel-system/#fuel-system-general-information__fuel-system-pressure-release) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/econoline-e250/2012-2013/remont/charging-system/#battery-battery-mounting-battery-cables) .
3. Position the secondary latch outward.
4. Squeeze both of the release tabs.
5. Remove the quick connect coupling from the tube.

Connect - Type IV

1. Install the quick connect coupling onto the tube until completely seated.
2. Apply the secondary latch into the locked position.
3. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/econoline-e250/2012-2013/remont/charging-system/#battery-battery-mounting-battery-cables) .

See also:
• FUEL TANK AND LINES
• INTRODUCTION - GASOLINE MODELS
• MODULE COMMUNICATIONS NETWORK
• MULTIFUNCTION ELECTRONIC MODULES
• BATTERY, MOUNTING AND CABLES
• INTERIOR TRIM AND ORNAMENTATION
• JACKING & LIFTING
• EVAPORATIVE EMISSION SYSTEM DTC CHART
• SYMPTOM CHART
• PINPOINT TEST A
• INSPECTION AND VERIFICATION
• SPECIFICATIONS
• FUEL SYSTEM PRESSURE RELEASE