fuel FORD FIESTA 2007 Workshop Manual

31 0-01 -8 Fuel Tank and Lines 31 0-01 -8 -- -
REMOVAL AND INSTALLATION
All except vehicles with diesel engine All
except vehicles with diesel engine
12. Disconnect the fuel tank vent pipe from the 14.
Disconnect the fuel pump module electrical '
evaporative emission canister. For connector.
additional information, refer to
Section 310-00 [Fuel System
- General
Information].
All vehicles
13' ~CAUTION:W~~~ lowering the fuel tank,
make sure that excessive strain is not
placed on the fuel lines and electrical
connectors.
Partially lower the fuel tank.
Vehicles with diesel engine
15. Disconnect the fuel level sensor electrical
connector.
All vehicles
16. N0TE:Make note of the color of the fuel
lines to make sure they are connected in
exactly the same positions when installing.
Fuel supply line connectors are white or
are identified by a white band. Fuel return
line connectors are red or are identified by
a red band.
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31 0-01 -9 Fuel Tank and Lines 31 Om01 -9
REMOVAL AND INSTALLATION
Disconnect the fuel supply and fuel return All except vehicle with diesel engine
lines from the fuel tank. For additional
I information, refer to Section 310-00 [Fuel 20. Using the special tool, loosen the fuel pump
module locking ring.
System
- General Information].
All exce~t vehicles with diesel engine 21 ACAUTION:M~~~ sure that the float or V
17. Disconnect the evaporative emissions
canister pipe.
-.
Squeeze the clip to release the pipe.
18.
Remove the evaporative emissions canister
from the fuel tank.
All vehicles
19. Remove the fuel tank assembly. arm
are not damaged while removing or
installing the fuel pump module.
Remove the fuel pump module.
I. Remove the locking ring.
2. Remove the O-ring seal.
Discard the O-ring seal.
3. Lift the module from the fuel tank.
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310-01 -1 0 Fuel Tank and Lines 31 0-01-10
REMOVAL AND INSTALLATION
Vehicles with diesel engine Installation
22. Using the special tool, loosen the fuel level WARNINGS: sensor locking ring.
A Do not smoke or carry lighted tobacco or
open flame of any type when working on
or near fuel related components. Highly
flammable vapors are always present and
may ignite. Failure to follow these
instructions may result in personal injury.
A This procedure involves fuel handling. Be
prepared for fuel spillage at all times and
always observe fuel handling precautions.
Failure to follow these instructions may
result in personal injury.
CAUTIONS:
23m &AUTION:M~~~ sure that the float or
arm are not damaged while removing or
installing the fuel level sensor.
Remove the fuel level sensor.
1. Remove the locking ring.
2. Remove the O-ring seal.
Discard the O-ring seal.
3. Lift the sensor from the fuel tank. Make
sure the fuel lines are connected in
the correct fuel-flow direction. Fuel supply
line connectors are white or are identified
by a white band. Fuel return line
connectors are red or are identified by a
red band.
A Make sure that the fuel supply and fuel
return lines click into place when installing
the lines. To make sure that the fuel lines
are fully seated, pull on the lines.
N0TE:lnstall a new O-ring seal.
N0TE:When installing the fuel tank make sure the
fuel lines do not get kinked or trapped.
N0TE:lnstall new fuel filler and vent pipe retaining
clamps.
N0TE:The fuel filler and vent pipe retaining clamps
must be installed in the same position as removed.
1. N0TE:Make sure that the arrows on the fuel
tank and the fuel pump module or fuel level
sensor are aligned correctly.
To install, reverse the removal procedure.
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31 0-01 -1 1 Fuel Tank and Lines 31 0-01 -1 1
REMOVAL AND INSTALLATION
Fuel Pump Module(23 534 0)

Removal
I. Remove the fuel pump module.
For additional information, refer to Fuel Tank
- in this section.
Installation
I. To install, reverse the removal procedure.
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31 0-01 -1 2 Fuel Tank and Lines 31 0-01-12
REMOVAL AND INSTALLATION
Fuel Tank Filler Pipe(23 572 0)
Removal
WARNINGS:
A Do not smoke or carry lighted tobacco or
open flame of any type when working on
or near any fuel related components.
Highly flammable vapours are always
present and can ignite. Failure to follow
these instructions may result in personal
injury.
A This procedure involves fuel handling. Be
prepared for fuel spillage at all times and
always observe fuel handling precautions.
Failure to follow these instructions may
result in personal injury.
I. Disconnect the battery ground cable. For
additional information, refer to
Section
41 4-01 [Battery, Mounting and
Cables].
2. Drain the fuel tank. For additional
information, refer to Section
31 0-00 [Fuel
System
- General Information].
3. Raise and support the vehicle. For additional
information, refer to Section
100-02 [Jacking
and Lifting].
4. Remove the left-hand rear fender splash
shield (road wheel shown removed for
clarity).
5. Remove the fuel tank filler pipe upper (.
retaining bolt.
'' &AUTION:W~~~ disconnecting the fuel
tank vent and fuel tank filler pipes, do not
use any sharp edge tools to lever off the
pipes. Failure to follow this instructions may
cause damage to the pipes.
N0TE:Make note of the positions of the retaining
clamps to make sure they are positioned in exactly
the same positions when installing.
Disconnect the fuel tank filler pipe and the
fuel tank vent pipe from the fuel tank.
Discard the retaining clamps.
2006.0 Fiesta 1212006 G210057en
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31 0-01 -1 3 Fuel Tank and Lines 31 0-01 -1 3
REMOVAL AND INSTALLATION
7. Remove the fuel tank filler pipe lower
retaining bolt and remove the fuel tank filler
i pipe.
Installation
WARNINGS:
A Do not smoke or carry lighted tobacco or
open flame of any type when working on
or near any fuel related components.
Highly flammable vapours are always
present and can ignite. Failure to follow
these instructions may result in personal
' injury.
A This procedure involves fuel handling. Be
prepared for fuel spillage at all times and
always observe fuel handling precautions.
Failure to follow these instructions may
result in personal injury.
N0TE:lnstall new fuel tank filler pipe and vent pipe
retaining clamps.
N0TE:The fuel tank filler pipe and vent pipe
retaining clamps must be installed in the same
position as removed.
1. To install, reverse the removal procedure.
2006.0 Fiesta 1212006 G210057en
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31 0-01 -1 4 Fuel Tank and Lines 310-01-14
REMOVAL AND INSTALLATION
Fuel Level Sensor
Removal
1. Remove the fuel level sensor.
For additional information, refer to Fuel Tank
in this section.
Installation
I. To install, reverse the removal procedure.
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310-01-15 Fuel Tank and Lines 31 0-01 -1 5
REMOVAL AND INSTALLATION
Fuel Level Resistor Card
Removal
All except vehicles with diesel engine Discard the fuel level resistor card
1. Remove the fuel pump and sender unit.
For additional information, refer to: Fuel Tank
(310-01 Fuel Tank and Lines, Removal and
Installation).
Vehicles with diesel engine
2. Remove the fuel level sensor.
For additional information, refer to: Fuel Tank
(310-01 Fuel Tank and Lines, Removal and
Installation).
All vehicles
3. N0TE:Diesel engine variants only have 2 Installation
wires. All vehicles
Disconnect the fuel level resistor card
electrical connectors.
ACAUTION:DO not touch the fuel level
I resistor card surface with tools or hands.
1 i Failure to follow this instruction may result
I in damage to the fuel level resistor card.
4. Using needle nose pliers, remove the fuel
level resistor card.
1. Press the locking tangs.
2. Remove the fuel level resistor card.
N0TE:Make sure that the locking tangs are in the
fully locked position.
N0TE:Make sure that the wiring harness is routed
around the fuel line,
in line with the original
installation.
Install the new fuel level resistor card into
the fuel pump and sender unit or the fuel
level sensor.
2. N0TE:t is not important which electrical
connector is connected to which fuel level
resistor card related pin in the top flange.
N0TE:Diesel engine variants only have 2 wires.
2006.0 Fiesta 1212006 G913201en
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31 0-01 -1 6 Fuel Tank and Lines 31 0-01 -1 6
REMOVAL AND INSTALLATION
Connect the fuel level resistor card electrical
connectors.
3. Make sure that the float rod and arm are able
to sweep their full ranges without contacting
or fouling on any wires.
Vehicles with diesel engine
4. N0TE:lnstall a new fuel level sensor gasket.
Install the fuel level sensor.
For additional information, refer to: Fuel Tank
(310-01 Fuel Tank and Lines, Removal and
InStallation).
All except vehicles with diesel engine
5. N0TE:lnstall a new fuel pump and sender
unit gasket.
Install the fuel pump and sender unit.
For additional information, refer to: Fuel Tank
(310-01 Fuel Tank and Lines, Removal and
Installation).
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Acceleration Control - I .3L Duratec-8V
(Rocam)llI25L Duratec-I 6V (Sigma)llI4L
31 0-02A-6 Duratec-I 6V (Sigma)/l .6L Duratec-1 6V (Sigma)
31 0-02A-6
DIAGNOSIS AND TESTING
PO653 - Sensor voltage supply circuit 2 short Inspection and Verification
to battery
- Check the power supply to the PCM (battery 1. Verify the customer concern.
voltage, relays, wiring harness and electrical 2. Visually inspect for obvious signs of mechanical
connectors as well as fuses). If no concern
or electrical damage.
- Follow WDS instructions. I - Accelerator pedal I Fuse(s) I
- is found, install a new PCM.
PI 71 2 - Electronic gear shift torque demand is Visual
Inspection Chart
N0TE:lf the vehicle is in a limited performance
mode, a system related DTC and the electronic
accelerator control fail light message will illuminate.
If there is a performance issue without these items
the electronic accelerator control system is running
correctly but another issue may exist elsewhere
on the vehicle.
not
a plausible signal (ASM only) - Linkage
- Accelerator cable
- Throttle body
Relay(s)
Wiring harness
Electrical
connector(s)
Accelerator pedal
Throttle body
Mechanical
Electrical
Symptom Chart < .I
Be
aware that installing new system related
components without these
DTCs will not improve
Symptom Chart
- Vehicles With 1.3L Engine
Symptom Possible Sources
Powertrain control
module (PCM)
Action
the
vehicle behavior for general issues such as:
high fuel consumption 3.
If an obvious cause for an observed or reported
concern is found, correct the cause (if possible)
poor idle quality before proceeding to the next step.
poor or no engine start
4. If the cause is not visually evident, verify the
symptom and refer to Symptom Chart.
f
Accelerator pedal is hard to
depress or has a
roughlraspy
or sticky feel
Damaged accelerator cable.
REFER to: Throttle Body (303-
04A, Removal and Installa-
tion).
INSTALL a new accelerator
cable.
Accelerator cable incorrectly installed.
Worn or damaged throttle body.
I Accelerator pedal does not I Weak or broken throttle body I INSTALL a new throttle body. I
CHECK the accelerator cable
for correct installation.
INSTALL a new throttle body.
return freely REFER to: Throttle Body (303-
04A, Removal and Installa-
tion).
I Worn or damaged throttle body. I INSTALL a new throttle body. I
I I I REFER to: Throttle Body (303- 1 04A, Removal and Installa-
tion).
High engine idle speed Damaged accelerator cable. INSTALL a new accelerator
I cable.
2006.0 Fiesta 1212006 G356253en
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