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Fuel System-General Information Ford Five Hundred I

Fuel System 13 illustrations ~960 words

GENERAL SPECIFICATIONS

ItemSpecification
Fuel tank capacity (Montego/Five Hundred)76 L (20 gallons)
Fuel tank capacity (Freestyle)72 L (19 gallons)
Fuel PressureFUEL SYSTEM SPECIFICATIONS
Lubricant
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-MC930-A

GENERAL SPECIFICATIONS

WARNINGDo not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.
WARNINGDo not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.

The fuel system consists of the

  1. fuel tank.
  2. fuel tank filler pipe.
  3. fuel pump module.
  4. fuel level sensor.
  5. fuel tubes.
  6. fuel filter.
  7. fuel injectors.
  8. fuel rail.
  9. fuel tank pressure transducer.
  10. inertia fuel shutoff (IFS) switch.
  11. fuel injection pressure temperature sensor.

The vehicle

  1. uses an electronic returnless fuel system.
  2. has a dual-container (saddle-type) fuel tank.
  3. has a fuel level sensor in the right fuel tank half.
  4. has a fuel pump module that supplies fuel under pressure to the fuel rail.
  5. has a fuel filter located on the passenger side in front of the fuel tank.
  6. is equipped with a sequential multi-port fuel injection (MFI) system.
  7. uses separately controlled fuel injectors for each cylinder. The fuel injectors are mounted to the intake manifold.
  8. fuel injectors are supplied with pressurized fuel from the fuel pump module to the fuel rail.
  9. fuel injection rail pressure is controlled by the electronic fuel delivery module which is enabled by the powertrain control module (PCM).
  10. has a fuel tank filler pipe assembly, which cannot be modified in any way and is serviced only by installation of a new fuel tank filler pipe assembly.
  11. has a fuel injection pressure sensor, which monitors the fuel pressure during running and key on/engine off conditions.
  12. has an inertia fuel shutoff (IFS) switch located in the passenger side footwell that shuts off fuel in the event of a collision.

Refer to the INTRODUCTION - GASOLINE article .

Fuel System Pressure Release

WARNINGDo not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.
WARNINGDo not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can 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 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.
  1. Remove the fuel pump fuse.
  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 released.
  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 3 seconds to pressurize the fuel system. Check for leaks before starting the engine.
  7. Start the vehicle and check the fuel system for leaks.

Special Tool(s)

SPECIAL TOOL DESCRIPTION Fuel Storage Tanker 164-R3202 or equivalent Wrench, Fuel Tank Sender Unit 310-123

Scheme 17

Scheme 17: Special Tool(s)
Scheme 17: Special Tool(s)

Draining

WARNINGDo not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.
WARNINGDo not carry personal electronic devices such as cell phones, pagers or audio equipment 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 can result in personal injury.
WARNINGThis procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury.

Scheme 18

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Scheme 22
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
  2. Release the fuel system pressure. For additional information, refer to «General Specifications»(/ford/five-hundred/i-2004-2007/remont/fuel-system/#fuel-system-general-information__general-specifications) .
  3. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/five-hundred/i-2004-2007/remont/charging-system/#battery-mounting-and-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 reaches the fuel tank inlet spout.
  6. Attach the fuel storage tanker to the fuel drain tube and remove any residual fuel remaining in the fuel tank filler pipe.
  7. Release the fuel tank filler pipe hose-to-fuel tank inlet spout clamp. To install, tighten to 3 Nm (27 lb-in).
  8. Remove the fuel tank filler pipe hose from the fuel tank inlet spout.
  9. Insert a suitable fuel drain tube into the fuel tank inlet spout.
  10. Attach the fuel storage tanker to the fuel drain tube and drain the fuel from the RH side of the fuel tank.
  11. Remove the rear lower seat cushion. Release the latches and pull upward on the rear lower seat cushion and remove.
  12. Position the second row seat forward.
  13. Remove the bolt and the LH third row rear seat load floor support. To install, tighten to 17 Nm (13 lb-ft).
  14. Remove the LH second row seat belt anchor bolt. To install, tighten to 30 Nm (22 lb-ft).
  15. Position aside the carpet and any insulation covering the fuel level sensor access cover.
  16. Remove the fuel level sensor access cover.
  17. Disconnect the fuel level sensor electrical connector.
  18. Clean the surrounding area of the fuel level sensor mounting flange.
  19. Install the special tool and remove the fuel level sensor lock ring.
  20. Carefully position the fuel level sensor aside.
  21. Install a suitable fuel drain tube into the fuel level sensor access hole in the fuel tank.
  22. Completely drain the remaining fuel from the LH side of the fuel tank.

Material

ItemSpecification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-M2C930-A

MATERIAL SPECIFICATIONS

Disconnection

WARNINGDo not carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable vapors are always present and can ignite. Failure to follow these instructions may result in personal injury.
WARNINGDo not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.
CAUTIONIf the liquid or vapor tube is damaged (torn, holes or delaminated), the affected tube assembly must be replaced with a new tube assembly. Do not use aftermarket sleeving. Do not re-adhere loose sleeving material.
CAUTIONWhen reusing liquid or vapor tube connectors, make sure to use compressed air or water to remove any foreign material from the connector retaining clip area before separating from the tube. Apply clean engine oil to the end of the tube before inserting the tube into the connector.
CAUTIONFuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or tubes.

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Scheme 24
  1. If servicing a liquid fuel tube, release the fuel system pressure. For additional information, refer to «FUEL SYSTEM PRESSURE RELEASE»(/ford/five-hundred/i-2004-2007/remont/fuel-system/#fuel-system-general-information__fuel-system-pressure-release) .
  2. If equipped, remove the redundant clip.
  3. Disconnect the quick connect coupling from the tube. Press the tube quick connect coupling release tab and pull the tube to disconnect.

Scheme 25

Scheme 25: Connection
Scheme 25: Connection
  1. Install the tube into the quick connect coupling.
  2. If equipped, install the redundant clip.

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Scheme 26: Removal
Scheme 26: Removal

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Scheme 27
Scheme 27
  1. Insert the tool that is supplied with the new replacement retainer clip into the quick connect coupling body until it engages and spreads the retainer legs.
  2. Grasp the retainer clip under the lip on each side, pull outward and remove while simultaneously removing the tool from the quick connect coupling body. The legs of the retainer clip may catch on the quick connect coupling body just prior to removal and you may need to open the legs of the retainer clip slightly to complete removal.
  3. Discard the quick connect coupling retainer clip.

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Scheme 28: Installation
Scheme 28: Installation

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Scheme 29
  1. Install the tool into the quick connect coupling body.
  2. Insert the legs of the new retainer clip into the windows on the body of the quick connect coupling body.
  3. Push the retainer clip straight into the quick connect coupling body until it is flush with the top lip and the side of the connector body.
  4. Push down the center of the retainer clip and remove the tool. Upon release the retainer clip should remain in the quick connect coupler body.

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