Ford Workshop Service and Repair Manuals

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

All vehicles

The fuel tank holds approximately 70 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 four retaining bolts onto the underside of the vehicle chassis.

Fuel tank ventilation is achieved by one fuel tank vent valve and a fill limit vent valve ventilating directly to atmosphere. The fuel tank vent valve will prevent fuel loss from the fuel tank if the vehicle becomes inverted.

Fuel lines

The fuel supply and return lines are constructed from PA nylon tubes and are retained by clips which are made of plastic. The fuel lines are protected under the vehicle by a plastic cover, which is clipped to welded studs.

Within the engine compartment, some fuel lines are produced from steel for improved robustness.

The fuel supply and return lines are separated into three sections. The fuel line connections have quick release couplings at each end to secure them to the fuel tank lines and front end fuel lines.
For additional information, refer to: Quick Release Coupling (310-00, General Procedures).

Fuel level sensor

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

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 measures the fuel level using a float and communicates 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 that the fuel tank level sensor float and arm are not damaged during the installation.

NOTE:Make sure that the installation marks are aligned.

The fuel tank must be completely removed from the vehicle before the fuel level sensor unit can be removed.
For additional information, refer to: Fuel Tank (310-01A, Removal and Installation).

Installation of a new fuel level sensor may not solve fuel indication issues which may occur during the vehicles life time.

Fuel filter - vehicles with 1.8L Duratorq-TDCi (Kent) diesel engine

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 fuel 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 (310-01C, Removal and Installation).

Fuel filter - vehicles with 2.0L Duratorq-TDCi (DW) diesel engine

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 retaining bracket, a fuel filter splash shield and a fuel filter crash protection shield are mounted to the 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 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 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 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 (310-01D, Removal and Installation).

Fuel tank vent valve

Fuel tank ventilation is achieved by a fuel tank vent valve and the fuel limit vent 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.

Fill limit vent valve

The fill limit vent valve is an intermediate ventilation valve between the fuel tank vent valve and the atmosphere.

The fill limit vent valve allows the fuel tank to be filled to its maximum, by expelling the air within the fuel tank to atmosphere.

The fill limit vent valve also acts as a fuel tank breather with a dust filter. If this dust filter becomes blocked or restricted during the vehicle's lifetime, problems will be experienced with draining the fuel tank. Also there could be a possibility of fuel tank deformation if the dust filter is blocked.