FORD MUSTANG 2003 Workshop Manual

4. Pull on the connection to make sure it is fully engaged. Klj . 3 ba
32003 Mustang Workshop Manual
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GENERAL PROCEDURES
Fittings —
Vapor Tube
Disconnect
1. WARNING: The evaporative emission system contains fuel vapor and condensed
fuel vapor. Although not present in large quantities, it still presents the danger of
explosion or fire. Disconnect the battery ground cable from the battery to minimize the
possibility of an electrical spark occurring, possibly causing a fire or explosion if fuel
vapor or fuel liquid is present in the area.
Disconnect the battery ground cable.
2. Disconnect the vapor tube from the fitting. 1. Squeeze the fitting.
2. Disconnect the vapor tube from the fitting.
Connect 1. Clean and inspect the fitting and the tube for damage.
2. Push the tube into the fitting until it snaps in place.
3. Pull on the connection to make sure the fitting is secure.
SECTION 310-
00: Fuel System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
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Klj . 2 ba
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SPECIFICATIONS
SECTION 310-
01: Fuel Tank and Lines 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants
Premium Long Life Grease
XG
-1-C or XG -1-K ESA-
M1C75- B Serfactant (Merpol) ESE-
M99B144- B
Torque Specifications Description Nm lb-
ft lb-
in Fuel tank support strap bolts 35 26 —
Fuel tank filler pipe support bracket bolt 8 — 71
Fuel delivery module bolts 10 — 89
Fuel filter bracket bolts 10 — 89 Klj . 1 ba
12003 Mustang Workshop Manual
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DESCRIPTION AND OPERATION
Fuel Tank And Lines
WARNING: Do not smoke, carry lighted tobacco or an open flame of any type when
working on or near any fuel- related component. Highly flammable mixtures are always present
and may be ignited, possibly resulting in personal injury.
The vehicle utilizes a returnless fuel system consisting of:
zthe fuel tank.
z a fuel tank filler pipe which contains a restrictor plate to permit only unleaded fuel to be pumped
into the fuel tank.
z a 1/8 turn fuel tank filler cap.
z a fuel filter providing filtration to protect the fuel injectors.
z a single fuel line accommodating the returnless fuel system.
z a fuel injection supply manifold which contains a differential pressure sensor and a fuel
temperature sensor.
z a fuel pump and sender assembly which provides pressurized fuel to the engine and contains:
„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 flow.
The fuel pump is controlled by an electronic fuel pump driver module which is enabled by the
powertrain control module (PCM). Electrical power to the fuel pump is provided through the inertia fuel
shutoff (IFS) switch, which is located in the luggage compartment. SECTION 310-
01: Fuel Tank and Lines 2003 Mustang Workshop Manual Klj . 1 ba
12003 Mustang Workshop Manual
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DIAGNOSIS AND TESTING
Fuel Tank And Lines
Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
SECTION 310-
01: Fuel Tank and Lines 2003 Mustang Workshop Manual Klj . 1 ba
12003 Mustang Workshop Manual
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REMOVAL AND INSTALLATION
Fuel Tank
Removal
WARNING: Do not smoke, carry lighted tobacco or an open flame of any type when
working on or near any fuel- related components. Highly flammable mixtures are always present
and may be ignited, possibly resulting in personal injury.
WARNING: Fuel supply lines on all vehicles equipped with fuel injected engines will
remain pressurized for long periods of time after engine shutdown. Fuel system pressure must
be relieved prior to fuel system service to prevent possible personal injury or a fire hazard.
1. Disconnect the battery. For additional information, refer to Section 414 - 01 .
2. Relieve the fuel system pressure. For additional information, refer to Section 310 - 00 .
3. Drain the fuel tank. For additional information, refer to Section 310 - 00 .
4. Raise the vehicle. For additional information, refer to Section 100 - 02 .
5. Remove the filler pipe bolt and disconnect the filler pipe hose connections to the fuel tank.
6. Disconnect the fuel tank electrical connector.
SECTION 310-
01: Fuel Tank and Lines 2003 Mustang Workshop Manual Material
Item Specification
Serfactant
(Merpol)
ESE-
M99B144- B Klj . 1 ba
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7. Disconnect the vapor tube fitting at the left front of the fuel tank.
8. Disconnect the EVAP canister tube and hose.
9. Place a safety support under the fuel tank.
10. Remove the front bolts from the fuel tank support straps and swing the LH strap out of the way. Klj . 2 ba
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11. Remove the RH fuel tank support strap bolt and remove the strap.
12. Partially lower the fuel tank and disconnect the fuel line. For additional information, refer to
Section 310 - 00 .
13. CAUTION: The filler pipe grommet must be removed prior to removing the fuel tank
from the filler pipe or damage to the fill tube check valve will occur.
Cut outer edge of pipe- to-tank grommet to facilitate pipe removal and carefully remove the
grommet from the fuel tank. Take care to avoid damage to the filler pipe check valve.
14. Lower the fuel tank from the vehicle.
Installation
1. CAUTION: Lubricate the filler pipe check valve area and the tank- to-filler pipe
grommet with Serfactant prior to assembly or damage to the filler pipe check valve will
occur.
NOTE: A new grommet must be used for the installation procedure due to its destruction during
removal. Klj . 3 ba
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To install, reverse the removal procedure. Klj . 4 ba
52003 Mustang Workshop Manual
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