Fuel System - General Information: Other Ford Flex I

3.5L

The fuel system

1. is a 2-speed Mechanical Returnless Fuel System (MRFS) with sequential Multi-Port Fuel Injection (MFI).
2. uses a dual-container (saddle-type) fuel tank.
3. has a fuel level sensor assembly.
4. has a Fuel Pump (FP) module that supplies fuel under pressure to the fuel rail.
5. has a lifetime fuel filter (serviced as part of the FP module).
6. has an Easy Fuel™ (capless) fuel tank filler pipe assembly, which cannot be modified in any way and is serviced only by the installation of a new fuel tank filler pipe assembly.
7. has a supplemental refueling adapter located in the spare tire compartment.
8. has a FP module that operates on 10 or 12 volts depending on load, that supplies fuel under pressure to the fuel rail.
9. has a FP control module located behind the RH C-pillar trim panel.
10. has fuel tubes (liquid and vapor) along with brake tubes mounted on the underside of the vehicle in a bundle.
11. has a FTP sensor (part of the fuel vapor tube assembly).
12. uses separately controlled fuel injectors for each cylinder. The fuel injectors are mounted to the intake manifold and are supplied with pressurized fuel from the FP module to the fuel rail.
13. fuel rail pressure is controlled by the electronic FP module which is enabled by the PCM.
14. has a serviceable fuel level sender mounted on the FP module.
15. has a serviceable fuel level sender mounted on the fuel level sensor assembly.

3.5L Gasoline Turbocharged Direct Injection (GTDI)

The fuel system

1. is a 2-speed Mechanical Returnless Fuel System (MRFS) with Gasoline Turbocharged Direct Injection (GTDI).
2. uses a dual-container (saddle-type) fuel tank.
3. has a fuel level sensor assembly.
4. has a FP module that operates on 10 or 12 volts depending on load, that supplies fuel under pressure to the high pressure FP .
5. has a lifetime fuel filter (serviced as part of the FP module).
6. has an Easy Fuel ™ (capless) fuel tank filler pipe assembly, which cannot be modified in any way and is serviced only by the installation of a new fuel tank filler pipe assembly.
7. has a supplemental refueling adapter located in the spare tire compartment.
8. has a fuel injection pump that supplies high pressure, low volume fuel to the fuel rails.
9. has a FP control module located behind the RH C-pillar trim panel.
10. has fuel tubes (liquid and vapor) along with brake tubes mounted on the underside of the vehicle in a bundle.
11. has a high pressure fuel tube from the fuel injection pump to the fuel rails.
12. has a Fuel Rail Pressure (FRP) sensor on the LH fuel rail.
13. has a FTP sensor (part of the fuel vapor tube assembly).
14. uses separately controlled fuel injectors for each cylinder. The fuel injectors are mounted directly into the head.
15. fuel injectors are supplied with pressurized fuel from the fuel injection pump to the fuel rail.
16. has a serviceable fuel level sender mounted on the FP module.
17. has a serviceable fuel level sender mounted on the fuel level sensor assembly.

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 FP control module. Signal communication between the RCM and the FP control module 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 to the OFF position and then turning the ignition to the ON position. In some instances the vehicle may not start the first time and may take one additional ignition cycle.

Fuel System Pressure Release

All vehicles

Material

MATERIAL SPECIFICATIONS

Disconnect - Type I

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 can occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector.

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 can occur. Always install plugs to any open orifices or tubes.

Note. Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks.

Scheme 27

Scheme 28

1. Disconnect the battery ground cable. For additional information, Refer to «BATTERY, MOUNTING AND CABLES»(ref-372793) .
2. Release the lock tab on the quick connect coupling.
3. Separate the quick connect coupling from the fitting.

Scheme 29

Scheme 30

1. NOTE: Apply clean engine oil to the O-ring seals. NOTE: Make sure the retainer clip is fully seated and locked onto the tube by pulling on the quick connect coupling. Release the lock tab and install the quick connect coupling onto the fitting.
2. Apply the lock tab into the latched position.
3. Connect the battery ground cable. For additional information, Refer to «BATTERY, MOUNTING AND CABLES»(ref-372793) .

Disconnect - Type II

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 can occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector.

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 can occur. Always install plugs to any open orifices or tubes.

Note. Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks.

Scheme 31

1. If servicing a liquid fuel tube quick connect coupling, release the fuel system pressure. For additional information, refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-372809-S21315480402010093000000) .
2. Disconnect the battery ground cable. For additional information, Refer to «BATTERY, MOUNTING AND CABLES»(ref-372793) .
3. NOTE: When reusing liquid or vapor tube quick connect couplings, make sure to use compressed air to remove any foreign material from the retaining clip area before disconnecting from the tube. Depress the retainer clip and disconnect the quick connect coupling from the tube.

Scheme 32

1. NOTE: Apply clean engine oil to the end of the tube and quick connect coupling O-ring seals. NOTE: Make sure the retainer clip is fully seated and locked onto the tube by pulling on the quick connect coupling. Install the quick connect coupling onto the tube until fully seated.
2. Connect the battery ground cable. For additional information, Refer to «BATTERY, MOUNTING AND CABLES»(ref-372793) .

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 can occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector.

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 can occur. Always install plugs to any open orifices or tubes.

Note. Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks.

Scheme 33

Scheme 34

1. If servicing a liquid fuel tube quick connect coupling, release the fuel system pressure. For additional information, refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-372809-S21315480402010093000000) .
2. Disconnect the battery ground cable. For additional information, Refer to «BATTERY, MOUNTING AND CABLES»(ref-372793) .
3. NOTE: When reusing liquid or vapor tube quick connect couplings, make sure to use compressed air to remove any foreign material from the retaining clip area before disconnecting from the tube. Apply clean engine oil to the end of the tube before connecting the quick connect coupling. 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.

Scheme 35

Scheme 36

1. NOTE: Apply clean engine oil to the end of the tube and quick connect coupling O-ring seals. Install the quick connect coupling onto the tube until fully seated.
2. NOTE: Make sure the retainer clip is fully seated and locked onto the tube by pulling on the quick connect coupling. Press the retainer clip into the quick connect coupling body until flush and the legs are locked in place.
3. Connect the battery ground cable. For additional information, Refer to «BATTERY, MOUNTING AND CABLES»(ref-372793) .

Disconnect - Type IV

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 can occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector.

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 can occur. Always install plugs to any open orifices or tubes.

Note. Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks.

Scheme 37

Scheme 38

1. If servicing a liquid fuel tube quick connect coupling, release the fuel system pressure. For additional information, refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-372809-S21315480402010093000000) .
2. Disconnect the battery ground cable. For additional information, Refer to «BATTERY, MOUNTING AND CABLES»(ref-372793) .
3. Depress the clip into the quick connect coupling.
4. Remove the quick connect coupling from the fitting.

Scheme 39

1. NOTE: Apply clean engine oil to the end of the tube and quick connect coupling O-ring seals. NOTE: Make sure the coupling is fully seated and locked onto the fitting by pulling on the quick connect coupling. Install the quick connect coupling onto the fitting until fully seated.
2. Connect the battery ground cable. For additional information, Refer to «BATTERY, MOUNTING AND CABLES»(ref-372793) .

MATERIAL SPECIFICATIONS

Disconnect

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 can occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector.

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 can occur. Always install plugs to any open orifices or tubes.

Scheme 40

Scheme 41

1. If servicing a liquid fuel tube spring lock coupling, release the fuel system pressure. For additional information, refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-372809-S21315480402010093000000) .
2. Disconnect the battery ground cable. For additional information, Refer to «BATTERY, MOUNTING AND CABLES»(ref-372793) .
3. Install the Spring Lock Coupling Disconnect Tool on the tube and push into the spring lock coupling to release.
4. Separate the spring lock coupling from the tube.

Scheme 42

1. NOTE: Lubricate the tube with clean engine oil. Align and push the spring lock coupling onto the tube until fully seated.
2. Pull on the coupling to make sure it is fully engaged.
3. Connect the battery ground cable. For additional information, Refer to «BATTERY, MOUNTING AND CABLES»(ref-372793) .