Fuel System - General Information Ford Taurus X I

Material

Material

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

The fuel system consists of the

1. fuel tank.
2. fuel tank filler pipe.
3. fuel tank filler cap.
4. fuel pump (FP) module.
5. fuel level sensor assembly (saddle-tank only).
6. fuel level sender (mounted on the FP and, if equipped, the fuel level sensor assembly).
7. fuel tubes.
8. fuel injectors.
9. fuel rail.
10. fuel tank pressure (FTP) sensor.
11. inertia fuel shutoff (IFS) switch.

The vehicle

1. uses a mechanical returnless fuel system.
2. uses either a single container (L-shaped) or a dual-container (saddle-type) fuel tank.
3. has a fuel level sensor assembly (saddle-tank only).
4. has a FP module that supplies fuel under pressure to the fuel rail.
5. has a fuel rail mounted Schrader valve on the early build vehicles.
6. has a fuel filter (part of the FP module).
7. has fuel tubes (liquid and vapor) along with brake tubes mounted on the underside of the vehicle in a bundle.
8. has a FTP sensor (part of the fuel vapor tube assembly).
9. is equipped with a sequential multi-port fuel injection (MFI) system.
10. uses separately controlled fuel injectors for each cylinder. The fuel injectors are mounted to the intake manifold.
11. fuel injectors are supplied with pressurized fuel from the FP module to the fuel rail.
12. fuel injection rail pressure is controlled by the electronic FP module which is enabled by the PCM.
13. has a 1/4 turn vented type fuel tank filler cap.
14. 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.
15. has an IFS switch located in the passenger side footwell that shuts off fuel in the event of a collision.
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 (saddle-tank only).
18. has a fuel level vent valve (part of the FP module on Taurus X federal emission vehicles, part of the fuel tank on all other vehicles).

Special Tools Illustration Tool Name Tool Number Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

Scheme 3

Principles of Operation

Note. The following procedure diagnoses a slow to fill concern only. For all other concerns, refer to the Introduction - Gasoline Engines article.

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 and a FP. 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

1. Verify the customer's 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/taurus-x/i-2007-2009/remont/communication-devices/#module-communications-network-system) article, No Power To The Scan Tool, to diagnose no communication with 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/taurus-x/i-2007-2009/remont/communication-devices/#module-communications-network-system) article 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/taurus-x/i-2007-2009/remont/communication-devices/#module-communications-network-system) article. 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 Table. For PCM related DTCs, refer to the «Introduction - Gasoline Engines»(/ford/taurus-x/i-2007-2009/remont/testing-diagnostics/#engine-controls-introduction-except-diesel-hybrid) article. For all other DTCs, refer to «MULTIFUNCTION ELECTRONIC MODULES»(/ford/taurus-x/i-2007-2009/remont/communication-devices/#multifunction-electronic-modules-system) article.
10. If no DTCs related to the concern are retrieved, go to «Symptom Chart»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information) .

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. 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, P1443, P1450, P1451 and P260F. Are any of these DTCs present? YES : REFER to «Introduction - Gasoline Engines»(/ford/taurus-x/i-2007-2009/remont/testing-diagnostics/#engine-controls-introduction-except-diesel-hybrid) article to diagnosis the EVAP system. NO : Go to A3 .
3. A3 MONITOR THE FUEL TANK PRESSURE (FTP) WHILE FILLING THE FUEL TANK Monitor the FTP reference value while filling the fuel tank. Refer to «Introduction - Gasoline Engines»(/ford/taurus-x/i-2007-2009/remont/testing-diagnostics/#engine-controls-introduction-except-diesel-hybrid) article. 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 Engines»(/ford/taurus-x/i-2007-2009/remont/testing-diagnostics/#engine-controls-introduction-except-diesel-hybrid) article. 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/taurus-x/i-2007-2009/remont/fuel-system/#fuel-tank-and-fuel-lines) article. 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 restrictions. If the restriction cannot be repaired, INSTALL a new fuel tank. REFER to «FUEL TANK AND LINES»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-tank-and-fuel-lines) article. NO : Taurus X federal emissions vehicles, go to A7 . All others, INSTALL a new fuel tank. REFER to «FUEL TANK AND LINES»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-tank-and-fuel-lines) article.
7. A7 CHECK TO MAKE SURE THAT THE FUEL LEVEL VENT VALVE IS FUNCTIONING CORRECTLY NOTE: The fuel level vent valve is part of the fuel pump (FP) module on the Taurus X federal emission vehicles. Remove the FP module. Refer to «FUEL TANK AND LINES»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-tank-and-fuel-lines) article. 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/taurus-x/i-2007-2009/remont/fuel-system/#fuel-tank-and-fuel-lines) article.

Fuel System Pressure Release

1. Remove the RH cowl side trim panel. For additional information, refer to Interior Trim - Exploded View in «INTERIOR TRIM AND ORNAMENTATION»(/ford/taurus-x/i-2007-2009/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) article.
2. Disconnect the inertia fuel shutoff (IFS) switch electrical connector.
3. Start the engine and allow it to idle until it stalls.
4. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel system pressure has been released.
5. Turn the ignition switch to the OFF position.
6. When the fuel system service is complete, reconnect the IFS switch.
7. Cycle the ignition key and wait 3 seconds to pressurize the fuel system.
8. Start the engine and check for leaks.
9. Install the RH cowl side trim panel. For additional information, refer to Interior Trim - Exploded View in «INTERIOR TRIM AND ORNAMENTATION»(/ford/taurus-x/i-2007-2009/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) article.

Fuel System Pressure Test

Special Tools Illustration Tool Name Tool Number Adapter, Fuel Pressure Test 310-180 Fuel Pressure Test Kit 310-D009 (D95L-7211A)

Vehicles with a fuel rail mounted Schrader valve

1. Remove the Schrader valve cap.
2. Install the Fuel Pressure Test Kit onto the Schrader valve test port located on the fuel rail.
3. Release the fuel system pressure. For additional information, refer to «Fuel System Pressure Release»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information__fuel-system-pressure-release) .
4. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/taurus-x/i-2007-2009/remont/body-electrical/#battery-mounting-and-cables) article.
5. Disconnect the fuel tube-to-fuel rail jumper tube quick connect coupling. For additional information, refer to «Quick Connect Coupling»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information__quick-connect-coupling) .
6. Install the Fuel Pressure Test Adapter and the Fuel Pressure Test Kit between the fuel tube and the fuel rail.
7. Connect the IFS switch electrical connector.
8. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/taurus-x/i-2007-2009/remont/body-electrical/#battery-mounting-and-cables) article.
9. Test the fuel system pressure to make sure it is within the specified range. For additional information, refer to «SPECIFICATIONS»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information) .

Fuel Tank Draining - Taurus, Sable

Special Tools Illustration Tool Name Tool Number Fuel Drain Hose 310-102 Fuel Storage Tanker 164-R3202 or equivalent Wrench, Fuel Tank Sender Unit 310-123

Vehicles with a saddle-type tank

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/taurus-x/i-2007-2009/remont/hoistjack/#jacking-and-lifting) article.
2. Release the fuel system pressure. For additional information, refer to «Fuel System Pressure Release»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information__fuel-system-pressure-release) .
3. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/taurus-x/i-2007-2009/remont/body-electrical/#battery-mounting-and-cables) article.
4. Release the fuel tank filler cap and position aside.
5. Insert the special tool into the fuel tank filler pipe. Attach the fuel storage tanker to the special tool and remove as much fuel as possible from the fuel tank and filler pipe, lowering the fuel level below the fuel pump (FP) module mounting flange.
6. Remove the rear seat lower cushion. For additional information, refer to «SEATING»(/ford/taurus-x/i-2007-2009/remont/seats/#seat-system) article.
7. Remove the FP module access cover.
8. Disconnect the FP module electrical connector.
9. Disconnect the fuel vapor tube assembly-to-FP module quick connect coupling. For additional information, refer to «Quick Connect Coupling»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information__quick-connect-coupling) .
10. Disconnect the fuel tank jumper tube-to-FP module quick connect coupling. For additional information, refer to «Quick Connect Coupling»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information__quick-connect-coupling) .
11. Remove the driveshaft. For additional information, refer to «DRIVESHAFT»(/ford/taurus-x/i-2007-2009/remont/driveshaft-universal-joints/#driveshaft) article.
12. Disconnect the fuel tank jumper tube-to-fuel tube quick connect coupling. For additional information, refer to «Quick Connect Coupling»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information__quick-connect-coupling) .
13. Remove the evaporative emission (EVAP) canister. For additional information, refer to «EVAPORATIVE EMISSIONS»(/ford/taurus-x/i-2007-2009/remont/auxiliary-emission-control-systems/#evaporative-emissions-system) article.
14. Position a suitable lift device under the fuel tank.
15. Remove the 2 front fuel tank strap bolts. To install, tighten to 35 Nm (26 lb-ft).
16. Partially lower the front of fuel tank.
17. Remove the 3 nuts and the FP module shield. To install, tighten to 9 Nm (80 lb-in).
18. Raise the fuel tank into the installed position and reinstall the 2 fuel tank strap bolts.
19. Install the special tool and remove the FP module lock ring.
20. Position the FP module aside, insert the tube from the fuel storage tanker into the FP module aperture and remove as much fuel as possible from the fuel tank.
21. Remove the fuel level sensor access cover.
22. Disconnect the fuel level sensor electrical connector.
23. Install the special tool and remove the fuel level sensor lock ring.
24. Position the fuel level sensor aside, insert the tube from the fuel storage tanker into the fuel level sensor aperture and remove as much of the remaining fuel as possible from the fuel tank.

Fuel Tank Draining - Taurus X

Special Tools Illustration Tool Name Tool Number Fuel Drain Hose 310-102 Fuel Storage Tanker 164-R3202 or equivalent Wrench, Fuel Tank Sender Unit 310-123

All vehicles

1. Release the fuel system pressure. For additional information, refer to «Fuel System Pressure Release»(/ford/taurus-x/i-2007-2009/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/taurus-x/i-2007-2009/remont/body-electrical/#battery-mounting-and-cables) article.
3. Release the fuel tank filler cap and position aside.
4. Insert the special tool into the fuel tank filler pipe. Attach the fuel storage tanker to the special tool and remove as much fuel as possible from the fuel tank and filler pipe, lowering the fuel level below the fuel pump (FP) module mounting flange.
5. Release the 2 load floor support brackets and position the load floor upward.
6. Remove the 4 load floor support-to-floor pan nuts and 2 brackets. To install, tighten to 18 Nm (13 lb-ft).
7. Remove the FP module access cover.
8. Disconnect the FP module electrical connector.
9. Disconnect the fuel tank jumper tube-to-FP module quick connect coupling. For additional information, refer to «Quick Connect Coupling»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information__quick-connect-coupling) .
10. Disconnect the fuel vapor tube assembly-to-FP module quick connect coupling. For additional information, refer to «Quick Connect Coupling»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information__quick-connect-coupling) .
11. Install the special tool and remove the FP module lock ring.
12. Position the FP module aside, insert the tube from the fuel storage tanker into the FP module aperture and remove as much fuel as possible from the fuel tank.
13. Remove the fuel level sensor access cover.
14. Disconnect the fuel level sensor electrical connector.
15. Disconnect the fuel vapor tube assembly-to-fuel level sensor quick connect coupling. For additional information, refer to «Quick Connect Coupling»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information__quick-connect-coupling) .
16. Disconnect the fuel vapor tube-to-fuel level sensor quick connect coupling. For additional information, refer to «Quick Connect Coupling»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information__quick-connect-coupling) .
17. Install the special tool and remove the fuel level sensor lock ring.
18. Position the fuel level sensor aside, insert the tube from the fuel storage tanker into the fuel level sensor aperture and remove as much of the remaining fuel as possible from the fuel tank.

Quick Connect Coupling

Material

Disconnect - Type I

1. If servicing a liquid fuel tube quick connect coupling, release the fuel system pressure. For additional information, refer to «Fuel System Pressure Release»(/ford/taurus-x/i-2007-2009/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/taurus-x/i-2007-2009/remont/body-electrical/#battery-mounting-and-cables) article.
3. Depress the retainer clip and disconnect the quick connect coupling from the tube.

Connect - Type I

1. 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»(/ford/taurus-x/i-2007-2009/remont/body-electrical/#battery-mounting-and-cables) article.

Disconnect - Type II

1. If servicing a liquid fuel tube quick connect coupling, release the fuel system pressure. For additional information, refer to «Fuel System Pressure Release»(/ford/taurus-x/i-2007-2009/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/taurus-x/i-2007-2009/remont/body-electrical/#battery-mounting-and-cables) article.
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. Install the quick connect coupling onto the tube until fully seated.
2. 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»(/ford/taurus-x/i-2007-2009/remont/body-electrical/#battery-mounting-and-cables) article.

Disconnect - Type III

1. If servicing a liquid fuel tube quick connect coupling, release the fuel system pressure. For additional information, refer to «Fuel System Pressure Release»(/ford/taurus-x/i-2007-2009/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/taurus-x/i-2007-2009/remont/body-electrical/#battery-mounting-and-cables) article.
3. Squeeze the quick connect coupling retainer locking tabs to release the locking mechanism.
4. Push the locking mechanism outward to release the tube.
5. Remove the quick connect coupling from the tube.

Connect - Type III

1. Install the quick connect coupling onto the tube.
2. Depress the quick connect coupling locking mechanism into the locked position.
3. Visually inspect and verify that the locking mechanism is flush with the quick connect coupling housing and that the locking tabs are securely fastened.
4. Pull on the quick connect coupling and the tube to make sure it is securely fastened.
5. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/taurus-x/i-2007-2009/remont/body-electrical/#battery-mounting-and-cables) article.

Spring Lock Couplings

Special Tools Illustration Tool Name Tool Number Spring Lock Coupling Disconnect Tool 310-S039 (T90T-9550-S) or equivalent

Material

Disconnect

1. Release the fuel system pressure. For additional information, refer to «Fuel System Pressure Release»(/ford/taurus-x/i-2007-2009/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/taurus-x/i-2007-2009/remont/body-electrical/#battery-mounting-and-cables) article.
3. Install the special tool on the tube and push into the spring lock coupling to release.
4. Separate the spring lock coupling from the tube.

Connect

1. 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»(/ford/taurus-x/i-2007-2009/remont/body-electrical/#battery-mounting-and-cables) article.

See also:
• FUEL PRESSURE SPECIFICATIONS
• Introduction - Gasoline Engines
• MODULE COMMUNICATIONS NETWORK
• MULTIFUNCTION ELECTRONIC MODULES
• FUEL TANK AND LINES
• INTERIOR TRIM AND ORNAMENTATION
• BATTERY, MOUNTING AND CABLES
• JACKING AND LIFTING
• SEATING
• DRIVESHAFT
• EVAPORATIVE EMISSIONS
• Symptom Chart
• Pinpoint Test A
• Fuel System Pressure Release
• Quick Connect Coupling