Ford Workshop Service and Repair Manuals

The fuel tank holds approximately 53 liters of usable fuel and is of a plastic construction. It is retained to the vehicle by means of two steel support straps, the fuel tank supports straps are secured by three retaining bolts onto the underside of the vehicle chassis.

The fuel tank filler pipe is designed to fill the fuel tank, it consists of a fuel tank filler pipe and fuel tank vent pipe. Located within the fuel tank filler pipe is a fuel filler pipe spit back valve. The spit back valves have been designed to reduce the possibility of fuel tank siphoning. To enable the hose of the fuel tank draining equipment to enter the fuel tank, it must pass through the fuel filler pipe spit back valve. For additional information on fuel tank draining.
For additional information, refer to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures).

The fuel tank filler pipe vent pipe allows air to escape from the tank when the fuel tank is being filled.

The fuel supply and return lines have either spring lock couplings or quick release couplings at each end to secure them to the fuel tank lines.
For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures) /
Spring Lock Couplings (310-00 Fuel System - General Information, General Procedures).

The fuel supply and return lines are constructed from a steel material coated with nylon and are retained by clips which are also made of plastic. At the front of the vehicle there is a fuel line grounding clip equipped with a conductive sleeve made of steel or conductive plastic which also holds the fuel supply and return lines against the body. This clip is made of a conductive material which is designed to dissipate the static electricity created when fuel travels through the fuel supply and return lines.

Fuel tank ventilation is achieved by a fuel tank roll-over valve which is installed into the top of the fuel tank and will prevent fuel loss from the fuel tank if the vehicle becomes inverted.

The fuel tank roll-over valve also acts as fuel tank breather with filter. If this filter become blocked or restricted during the vehicle's lifetime the customer will experience problems with draining the fuel tank and there could be a possibility of fuel tank deformation.

The fuel level sensor is located in the top of the fuel tank and retained by a fuel level sensor locking ring and seal, a new seal must installed after the fuel level sensor is removed.

NOTE:The fuel tank must be completely removed from the vehicle before the fuel level sensor can be removed.

For additional information, refer to: Fuel Tank - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Kent) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Vehicles Without: Fuel Fired Booster Heater/Fuel Additive Tank (310-01 Fuel Tank and Lines, Removal and Installation).

The fuel level sensor is equipped with a fuel tank sender unit. The fuel tank sender unit consists of a mechanical float and a potentiometer. The potentiometer communicates the fuel level information via a float directly with the fuel gauge in the instrument cluster informing the driver the amount of fuel that is currently in the fuel tank.

CAUTION:Make sure the fuel level sensor float and arm are not damaged during the removal or installation of the fuel level sensor.

NOTE:Make sure the arrows on the fuel tank and fuel level sensor are aligned correctly. Failure to follow this may result in incorrect fuel gauge reading.

Vehicles with 1.6L Duratorq-TDCi (DV) diesel engine

Fuel Filter

The 1.6L Duratorq-TDCi (DV6) diesel engine fuel filter is located above the gearbox and is attached to the cylinder head by means of a fuel filter shield and fuel filter retaining bracket. The fuel filter has an electric fuel heater which is located below the fuel filter inlet pipe. The fuel filter forms a single component with the housing and can only be renewed as a complete unit.
For additional information, refer to: Fuel Filter - 1.6L Duratorq-TDCi (DV) Diesel (310-01 Fuel Tank and Lines, Removal and Installation).

When the temperature is below 15ºC, a valve inside the fuel filter opens allowing fuel which is pre-heated by the fuel injection pump to be recirculated back through the fuel filter to the fuel injection pump. This aids engine performance during warm up.

Fuel is delivered through the fuel supply lines to the fuel filter. The fuel filter cleans the fuel of water and contaminants. Unused fuel is returned to the fuel pump supply line and eventually returned directly to the fuel tank.

After the fuel filter has been replaced it must be bled with a hand pressure pump. Make sure that the arrows indicating the direction of fuel flow is pointing towards the fuel filter.
For additional information, refer to: Fuel Filter - 1.6L Duratorq-TDCi (DV) Diesel (310-01 Fuel Tank and Lines, Removal and Installation).

Vehicles with 1.8L Duratorq-TDCi (Kent) diesel engine

Fuel Filter

The 1.8L Duratorq-TDCi (Kent) diesel engine fuel filter is located above the transmission and is attached to the cylinder head by means of a fuel filter retaining bracket. The fuel filter has an electric fuel heater which is located next to the fuel pump fuel supply line.

When the temperature is below 15ºC, a valve inside the fuel filter opens, allowing fuel which is pre-heated by the fuel pump to be recirculated back through the fuel filter to the fuel pump. This aids engine performance during warm up.

Fuel is delivered through the fuel supply line to the fuel filter. The fuel filter cleans the fuel of water and contaminants. Unused fuel is returned to the fuel tank through the fuel pump fuel return line.

When a new fuel filter has been installed it must be bled using a hand pressure pump. Make sure that the arrows indicating the direction of fuel flow is pointing towards the fuel filter.
For additional information, refer to: Fuel Filter - 1.8L Duratorq-TDCi (Kent) Diesel, Vehicles Without: Water-in-Fuel Sensor (310-01 Fuel Tank and Lines, Removal and Installation).

Vehicles with 2.0L Duratorq-TDCi (DW) diesel engine

Fuel Filter

CAUTION:The generator must be protected from contamination. Failure to follow this instruction may cause premature failure of the generator.

The 2.0L Duratorq-TDCi (DW) diesel engine fuel filter is located above the generator and is attached to the cylinder head by means of a fuel filter crash protection shield, a fuel filter splash shield and a fuel filter retaining bracket. The fuel filter has an electric fuel heater which is located next to the fuel filter inlet pipe.

When the temperature is below 15ºC, a valve inside the fuel filter opens allowing fuel which is pre-heated by the fuel injection pump to be recirculated back through the fuel filter to the fuel injection pump. This aids engine performance during warm up.

Fuel is delivered through the fuel supply lines to the fuel filter. The fuel filter cleans the fuel of water and contaminants. Unused fuel is returned to the fuel tank through the fuel pump return line.

The fuel filter is also equipped with a water-in-fuel sensor which is located at the base of the fuel filter housing. This sensor measures the amount of water which has collected in the fuel filter element. If the quantity of water present is greater than 90 ml then a warning indicator located on the instrument cluster is illuminated and the fuel filter element should then be drained of water.

When a new fuel filter has been fitted it must be bled with a hand pressure pump. Make sure that the arrows indicating the direction of fuel flow is pointing towards the fuel filter.
For additional information, refer to: Fuel Filter - 2.0L Duratorq-TDCi (DW) Diesel, Vehicles Without: Water-in-Fuel Sensor (310-01, Removal and Installation).

Vehicles with fuel additive system

System Overview

WARNING:Eye, hand, ear protection and protective clothing are required to be worn during any general service work or removal and installation of fuel additive system components. Failure to follow this instruction may result in personal injury.

WARNING:In case of fuel additive fluid contact with the skin or the eyes, flush immediately with water for a minimum of 15 minutes and seek prompt medical attention. Failure to follow these instructions may result in personal injury.

WARNING:If fuel additive fluid is swallowed, call a physician immediately. rinse mouth immediately with water, do not induce vomiting. Failure to follow these instructions may result in personal injury.

WARNING:Always provide adequate ventilation when working on the fuel additive fluid system or related components. Failure to follow these instructions may result in personal injury.

WARNING:Do not smoke or 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 may ignite. Failure to follow these instructions may result in personal injury.

CAUTION:Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible. Foreign matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel system and may result in later malfunction.

The fuel additive system supports the diesel particulate filter (DPF) to reduce the pollution generated by diesel vehicles by filtering solid elements out of the exhaust gases to reach stage 4 emission levels.

The additive system consists of a fuel additive system module, fuel additive tank to fuel tank line and a fuel additive tank with integral dosing pump. The fuel additive fluid is used to lower the combustion temperature of the unburnt fuel residues inside the DPF. The additive fluid, which contains cerium and iron must be exactly mixed with the fuel in the main fuel tank to achieve the right level when entering the DPF.

After fuel tank filling has been completed by the customer the fuel additive system module communicates information to the additive tank which injects a calculated dose of additive fluid into the main fuel tank when the vehicle reaches or exceeds a speed of 40 kph or 4 minutes after the fuel tank filling has been completed. The fuel additive system module uses signals and information from the CAN-bus ,engine on/off signal, vehicle speed sensors and fuel gauge value from instrument cluster. It will also initially receive a signal from the fuel filler pipe filler flap switch to indicate that a fill up procedure may be about to occur.

Routine service interval maintenance is required for this system.
For additional information, refer to: Fuel Additive System Filling and Bleeding (310-00 Fuel System - General Information, General Procedures).

The fuel additive tank holds approximately 1.4 liters of usable fuel additive fluid and approximately 1.8 usable liters when completely refilled and is of a plastic construction. It is retained to the vehicle by means of three retaining bolts which are fitted to the top of the rear sub-frame on the underside of the vehicle chassis.

The fuel additive tank is also equipped with a internal dosing pump which is an integral part of the fuel additive tank. The dosing pump receives a signal from the fuel additive system module and adds the correct amount of fuel additive to the main fuel tank. The fuel additive tank and dosing pump are a one piece unit and cannot be serviced separately.
For additional information, refer to: Fuel Additive Tank (310-01 Fuel Tank and Lines, Removal and Installation).

The fuel additive system module controls the amount and frequency of fuel additive fluid injecting into the main fuel tank. It is retained to the vehicle by means of two retaining nuts and is located underneath the rear seat carpet.
For additional information, refer to: Fuel Additive System Module (310-01 Fuel Tank and Lines, Removal and Installation).

Vehicles with 1.6L Duratec-16V (Sigma) engine/1.6L Duratec-16V Ti-VCT (Sigma) engine/1.8L Duratec-HE (MI4) engine or 2.0L Duratec-HE (MI4) engine

System Overview

The fuel tank holds approximately 55 liters of usable fuel and is of a plastic construction. It is retained to the vehicle by means of two steel support straps, the fuel tank supports straps are secured by three retaining bolts onto the underside of the vehicle chassis.

The fuel tank filler pipe is designed to fill the fuel tank it consists of a fuel tank filler pipe and fuel tank vent pipe, located within the fuel tank filler pipe is a fuel filler pipe spit back valve. The spit back valve has been designed to reduce the possibility of fuel tank siphoning. To enable the hose of the fuel tank draining equipment to enter the fuel tank, it must pass through the fuel filler pipe spit back valve. For additional information on fuel tank draining.
For additional information, refer to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures).

The fuel tank filler pipe vent pipe allows air to escape from the tank when the fuel tank is being filled.

Fuel tank ventilation is achieved by two fuel tank roll - over valves venting through a back pressure valve and into an evaporative emission canister which absorbs the fuel vapor. The fuel tank roll - over valve are installed into the top of the fuel tank and will prevent fuel loss from the fuel tank if the vehicle becomes inverted.

The fuel pump module is located in the top of the fuel tank and retained by a re-usable fuel tank locking ring. The fuel pump module seal must not be re-used once removed from the fuel tank.

The fuel pump module consists of a fuel sender, a fuel filter and a high pressure fuel pump with pressure regulator. The fuel filter is designed to reduce the amount of large fuel debris entering the main fuel system filter. The fuel tank module filter has been designed as a non serviceable item and will last the lifetime of the vehicle, if the fuel tank module filter becomes blocked a new fuel pump module must be installed
For additional information, refer to: Fuel Pump Module (310-01 Fuel Tank and Lines, Removal and Installation).
The fuel pump is a turbine type pump which is an integral part of the fuel pump module. The fuel tank module fuel sender communicates directly with the instrument cluster which drives the fuel gauge informing the driver the amount of fuel that is currently in the fuel tank.

CAUTION:Make sure the fuel tank level sensor float and arm are not damaged during the installation of the fuel pump module.

NOTE:Make sure the arrows on the fuel tank and fuel pump module are aligned correctly. Failure to follow this may result in incorrect fuel gauge reading.

The fuel tank must be completely removed from the vehicle before the fuel pump module unit can be removed.
For additional information, refer to: Fuel Tank - 1.6L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT (Sigma)/1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4)/2.5L Duratec-ST (VI5), Vehicles Without: Fuel Fired Booster Heater (310-01 Fuel Tank and Lines, Removal and Installation).

The fuel supply line has either spring lock couplings or quick release couplings at each end to secure it to the fuel tank.
For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures) /
Spring Lock Couplings (310-00 Fuel System - General Information, General Procedures).

The fuel supply line is constructed from a steel material coated with nylon and is retained by clips which are also made of plastic. At the front of the vehicle there is a fuel line grounding clip equipped with a conductive sleeve made of steel or conductive plastic which also holds the fuel supply line against the body. This clip is made of a conductive material which is designed to dissipate the static electricity created when fuel travels through the fuel supply line.

Vehicles with 1.6L Duratec-16V (Sigma) engine/1.6L Duratec-16V Ti-VCT (Sigma) engine/1.8L Duratec-HE (MI4) engine or 2.0L Duratec-HE (MI4) engine are equipped with a returnless fuel system. The returnless fuel system eliminates fuel system recirculation therefore reducing fuel heating and evaporative emissions. A fuel pressure sensor located in the fuel tank module controls a constant fuel rail pressure under all driving conditions.

The inertia fuel shutoff (IFS) switch cuts off the electrical supply to the fuel pump in the event of an accident and is located in the right hand footwell behind the front scuff plate trim panel.
For additional information, refer to: Front Scuff Plate Trim Panel (501-05 Interior Trim and Ornamentation, Removal and Installation).