ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

Diagnosis and Testing > < Quick Release Coupling
Fuel Tank and Lines - 1.25L/1.3L/1.4L/1.6L - Fuel Tank and Lines Fiesta 1996 (08/1995-02/2002)
Description and Operation

The fuel system comprises a rear mounted fuel tank, an in-tank fuel pump/sender unit (in the case of petrol variants), a fuel tank filler pipe, a fuel filter, a fuel heater (in the case of diesel variants) and a number of fuel supply and return lines.

The fuel tank is of steel construction and has a capacity of 42 litres. The fuel tank is fixed to the vehicle by means of four bolts. Fuel tank ventilation is achieved via a fuel tank roll -over valve (into an evaporative emission canister in the case of petrol variants). The fuel tank roll-over valve prevents fuel loss from the fuel tank if the vehicle becomes inverted.

The fuel pump is located inside the fuel tank and is fixed to the top of the tank by a locking ring. The fuel pump is of the regenerative turbine type and will deliver fuel at a rate of 80 lph at a pressure of 3.0 bar. The fuel pump has an integral fuel tank sender unit and features excellent hot fuel handling, low noise, highly reliable operation and integral radio frequency interference (RFI) protection.

The fuel tank filler pipe is of plastic construction and is fixed to the vehicle by means of two bolts. The fuel tank filler pipe is fitted with a locking filler cap which seals the system.

The fuel supply and return lines are made of a combination of plastic, steel and rubber. Plastic fuel pipes are connected to the fuel tank, fuel injection pump (in the case of diesel variants) and fuel filter and fuel resistant rubber pipes are connected to the fuel rail (in the case of petrol variants). The plastic and rubber pipes are joined by means of two steel pipes which run along the underside of the vehicle. All fuel pipe connectors are of the quick -release type. Supply pipe connectors are white or are identified by a white band. Return pipe connectors are red or identified by a red band.

The fuel filter (in the case of petrol variants) is located on the leading edge of the fuel tank. The fuel filter clamp is fixed to the fuel tank bymeans of two rivets and the fuel filter retained by the clamp with a single bolt.

The fuel filter (in the case of diesel variants) is located on the rear face of the cylinder head, adjacent to the battery tray. The fuel filter clamp is fixed to the cylinder head using two of the bolts which retain the rear engine lifting eye. The fuel filter is retained by the clamp with a single bolt.

both petrol and diesel fuel filters have a paper element contained within a steel canister.

The diesel fuel heater is located on the rear of the cylinder block in front of the fuel filter. The diesel fuel heater bracket is fixed to the cylinder block by a single bolt and the diesel fuel heater is retained to the bracket by two clips.

The diesel fuel heater is designed to warm diesel fuel in order to prevent waxing at cold temeratures. The heating element is a temperature dependent resistance which has a positive temperature coefficient, ie., the resistance of the heating element increases with increasing temperature. The heater is fitted with an integral thermoswitch which prevents overheating of the heater element.

A fuel shut-off switch (in the case of petrol variants) is located behind the passenger cowl side trim panel adjacent to the powertrain control module. The fuel shut -off switch is designed to cut the electrical supply to the fuel pump in the event of an accident or parking impact, thus reducing the risk of fire.

Diagnosis and Testing > < Quick Release Coupling