Fuel System-General Information Lincoln Zephyr US

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

The fuel system consists of

1. A fuel rail.
2. A multi-port fuel injection (MFI) system.
3. A standard fuel tank.
4. Fuel tubes.
5. A fuel tank filler pipe assembly, which cannot be modified in any way, that also contains a restrictor plate to permit only unleaded fuel to be pumped into the tank.
6. A 1/4 turn-type fuel tank filler cap.
7. An inertia fuel shutoff (IFS) switch.
8. A fuel pump module (FPM) containing: The electric fuel pump, which provides pressurized fuel to the fuel rail. The fuel level sensor. An inlet filter. A check valve, which maintains system pressure after the pump is shut off. A pressure relief valve for overpressure protection in the event of restricted fuel flow. A fuel filter providing filtration to protect the fuel injectors from foreign material. The fuel pump is controlled by the powertrain control module (PCM). Electrical power to the pump is provided through the IFS switch located under the right front kick panel. The engines are equipped with sequential multi-port fuel injection. The fuel pressure is regulated to a constant pressure by an intake pressure regulator.

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

Principles of Operation

Note. The following procedure diagnoses a slow to fill concern only. For all other concerns refer to the INTRODUCTION - GASOLINE 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 «PINPOINT TEST P: NO MODULE/NETWORK COMMUNICATION -- NO POWER TO THE DIAGNOSTIC TOOL»(/lincoln/zephyr/us-2006-2006/remont/communication-devices/#module-communications-network) 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»(/lincoln/zephyr/us-2006-2006/remont/communication-devices/#module-communications-network) to diagnose no response from the powertrain control module (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»(/lincoln/zephyr/us-2006-2006/remont/communication-devices/#module-communications-network) . If the network test passes, retrieve and record continuous memory diagnostic trouble codes (DTCs).
8. Clear the continuous DTCs and carry out the self-test diagnostics for the evaporative emission (EVAP) system.
9. If the DTCs retrieved are related to the concern, go to «EVAPORATIVE EMISSION SYSTEM DIAGNOSTIC TROUBLE CODE CHART»(/lincoln/zephyr/us-2006-2006/remont/fuel-system/#fuel-system-general-information) . For PCM related DTCs, refer to the «INTRODUCTION - GASOLINE»(ref-249149) article. For all other DTCs, refer to «MULTIFUNCTION ELECTRONIC CONTROL MODULES»(/lincoln/zephyr/us-2006-2006/remont/communication-devices/#multifunction-electronic-control-modules) .
10. If no DTCs related to the concern are retrieved, GO to «SYMPTOM CHART»(/lincoln/zephyr/us-2006-2006/remont/fuel-system/#fuel-system-general-information__symptom-chart) . EVAPORATIVE EMISSION SYSTEM DIAGNOSTIC TROUBLE CODE CHART DTC Description Action P0446 Evaporative Emission System Vent Control Circuit GO to «PINPOINT TEST A»(/lincoln/zephyr/us-2006-2006/remont/fuel-system/#fuel-system-general-information__pinpoint-test-a-slow-to-fill) . P0451 Evaporative Emission System Pressure Sensor/Switch Range/Performance GO to «PINPOINT TEST A»(/lincoln/zephyr/us-2006-2006/remont/fuel-system/#fuel-system-general-information__pinpoint-test-a-slow-to-fill) . P0452 Evaporative Emission System Pressure Sensor/Switch Low GO to «PINPOINT TEST A»(/lincoln/zephyr/us-2006-2006/remont/fuel-system/#fuel-system-general-information__pinpoint-test-a-slow-to-fill) . P0453 Evaporative Emission System Pressure Sensor/Switch High GO to «PINPOINT TEST A»(/lincoln/zephyr/us-2006-2006/remont/fuel-system/#fuel-system-general-information__pinpoint-test-a-slow-to-fill) . P0454 Evaporative Emission System Pressure Sensor/Switch Intermittent GO to «PINPOINT TEST A»(/lincoln/zephyr/us-2006-2006/remont/fuel-system/#fuel-system-general-information__pinpoint-test-a-slow-to-fill) . P1443 Evaporative Emission System Control Valve (Low/No Flow) GO to «PINPOINT TEST A»(/lincoln/zephyr/us-2006-2006/remont/fuel-system/#fuel-system-general-information__pinpoint-test-a-slow-to-fill) . P1450 Unable to Bleed up Fuel Tank Vacuum GO to «PINPOINT TEST A»(/lincoln/zephyr/us-2006-2006/remont/fuel-system/#fuel-system-general-information__pinpoint-test-a-slow-to-fill) . P1451 Evaporative Emission System Vent Control Circuit GO to «PINPOINT TEST A»(/lincoln/zephyr/us-2006-2006/remont/fuel-system/#fuel-system-general-information__pinpoint-test-a-slow-to-fill) . P260F Emission System Monitoring Processor Performance GO to «PINPOINT TEST A»(/lincoln/zephyr/us-2006-2006/remont/fuel-system/#fuel-system-general-information__pinpoint-test-a-slow-to-fill) .

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.

Possible Causes

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 (part of the fuel tank)

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 EVAPORATIVE EMISSION (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»(ref-249149) 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 fuel tank pressure (FTP) reference value while filling the fuel tank. REFER to «INTRODUCTION - GASOLINE»(ref-249149) 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. Refer to «QUICK CONNECT COUPLING»(/lincoln/zephyr/us-2006-2006/remont/fuel-system/#fuel-system-general-information__quick-connect-coupling) . Monitor the FTP reference value while filling the fuel tank. REFER to «INTRODUCTION - GASOLINE»(ref-249149) article. Is FTP within specification? Yes : INSPECT the EVAP system for blockage or restrictions. REPAIR the blockage or restriction. If the restriction or blockage 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 & LINES»(/lincoln/zephyr/us-2006-2006/remont/fuel-system/#fuel-tank-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 filler pipe inlet check valve restricted or sticking? Yes : If possible, REPAIR the restriction. If the restriction cannot be repaired, INSTALL a new fuel tank. REFER to «FUEL TANK & LINES»(/lincoln/zephyr/us-2006-2006/remont/fuel-system/#fuel-tank-lines) . No : INSTALL a new fuel tank. REFER to «FUEL TANK & LINES»(/lincoln/zephyr/us-2006-2006/remont/fuel-system/#fuel-tank-lines) .

Fuel System Pressure Release

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 relay.
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.

Fuel Tank Draining

SPECIAL TOOL(S) DESCRIPTION Fuel Storage Tanker 164-R3202 or equivalent Fuel Draining Hose 310-102 Fuel Tank Lock Ring Wrench 310-123

Scheme 3

Scheme 4

Scheme 5

Scheme 6

1. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM PRESSURE RELEASE»(/lincoln/zephyr/us-2006-2006/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»(/lincoln/zephyr/us-2006-2006/remont/body-electrical/#battery-mounting-and-cables) .
3. Release the fuel tank filler cap and position aside.
4. Insert the special tool into the fuel tank filler pipe.
5. Attach the fuel storage tanker to the special tool and remove as much fuel as possible from the fuel tank and fuel tank filler pipe.
6. Remove the rear seat lower cushion. For additional information, refer to «SEATING»(/lincoln/zephyr/us-2006-2006/remont/seats/#seating) .
7. Position the carpet and/or any insulation covering the fuel pump module access cover.
8. Remove the 4 screws and the fuel pump module access cover.
9. Disconnect the fuel pump module electrical connector.
10. Disconnect the fuel supply tube-to-fuel pump module quick connect coupling.
11. Using the special tool, remove the fuel pump module lock ring retainer.
12. Position the fuel pump module aside and insert the tube from the fuel storage recovery tanker. Completely drain the fuel from the fuel tank.

Quick Connect Coupling

SPECIAL TOOL(S) DESCRIPTION Disconnect Tool, Quick Connect Coupling 310-040

Scheme 7

MATERIAL SPECIFICATION

Disconnect - Type I

Scheme 8

1. If servicing a liquid fuel tube quick connect coupling, release the fuel system pressure. For additional information, refer to «FUEL SYSTEM PRESSURE RELEASE»(/lincoln/zephyr/us-2006-2006/remont/fuel-system/#fuel-system-general-information__fuel-system-pressure-release) .
2. Disconnect the fuel tube quick connect coupling. Press the fuel tube quick connect coupling button and pull the fuel tube to disconnect.

1. Install the quick connect coupling onto the tube until it is fully seated.

Disconnect - Type

Scheme 9

Scheme 10

1. Release the lock tab on the coupling.
2. Separate the coupling from the fitting.

Scheme 11

1. Release the lock tab and install the coupling onto the fitting.
2. Apply the lock tab into the latched position.

Disconnect - Type

Scheme 12

Scheme 13

Scheme 14

Scheme 15

1. If servicing a liquid fuel tube quick connect coupling, release the fuel system pressure. For additional information, refer to «FUEL SYSTEM PRESSURE RELEASE»(/lincoln/zephyr/us-2006-2006/remont/fuel-system/#fuel-system-general-information__fuel-system-pressure-release) .
2. Release the quick connect coupling lock tab.
3. Rotate the primary locking tab to the fully opened position and squeeze the secondary locking tabs to release the locking mechanism.
4. Push the locking mechanism outward and release the fuel supply tube.
5. Remove the quick connect coupling from the tube.

1. Install the quick connect coupling onto the tube until it is fully seated.
2. Depress the retainer clip until it is flush with the quick connect coupler housing and is fully seated on the tube.
3. Rotate the primary locking tab on the retainer clip to the closed position.

Disconnect - Type IV

Scheme 16

Scheme 17

Scheme 18

1. If servicing a liquid fuel tube quick connect coupling, release the fuel system pressure. For additional information, refer to «FUEL SYSTEM PRESSURE RELEASE»(/lincoln/zephyr/us-2006-2006/remont/fuel-system/#fuel-system-general-information__fuel-system-pressure-release) .
2. Squeeze the quick connect coupling retainer clip tabs to release the locking mechanism.
3. Push the locking mechanism outward to release the tube.
4. Remove the quick connect coupling from the tube.

Scheme 19

Scheme 20

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 tabs are locked in place.

Disconnect - Type V

1. Install the special tool on the tube and push into the quick connect coupling locking clip to release.
2. Remove the quick connect coupling from the tube.

1. Install the quick connect coupling onto the tube until it is fully seated.

See also:
• FUEL PRESSURE SPECIFICATIONS
• PINPOINT TEST P: NO MODULE/NETWORK COMMUNICATION -- NO POWER TO THE DIAGNOSTIC TOOL
• MULTIFUNCTION ELECTRONIC CONTROL MODULES
• FUEL TANK & LINES
• BATTERY, MOUNTING AND CABLES
• SEATING
• EVAPORATIVE EMISSION SYSTEM DIAGNOSTIC TROUBLE CODE CHART
• SYMPTOM CHART
• PINPOINT TEST A
• QUICK CONNECT COUPLING
• FUEL SYSTEM PRESSURE RELEASE