FORD KUGA 2011 1.G Workshop Manual

SECTION 310-01 Fuel Tank and Lines
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
DESCRIPTION AND OPERATION
310-01-2
Fuel Tank and Lines — 2.5L Duratec (147kW/200PS) - VI5 (Component Location) .........
310-01-5
Fuel Tank and Lines — 2.5L Duratec (147kW/200PS) - VI5 (Overview) ............................
310-01-5
Fuel tank ........................................................................\
.....................................................
310-01-5
Fuel pump and sender unit ........................................................................\
.........................
310-01-6
Fuel filler pipe and tank cap........................................................................\
........................
REMOVAL AND INSTALLATION 310-01-8
Fuel Tank — 2.5L Duratec (147kW/200PS) - VI5 ...............................................................
310-01-11
Fuel Level Sensor — 2.5L Duratec (147kW/200PS) - VI5 .................................................
310-01-12
Fuel Tank Filler Pipe ........................................................................\
...................................
310-01-14
Fuel Filler Nozzle Inhibitor ........................................................................\
..........................
310-01-18
Fuel Pump and Sender Unit — 2.5L Duratec (147kW/200PS) - VI5 ..................................
310-01-1
Fuel Tank and Lines
310-01- 1
.
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Fuel Tank and Lines — 2.5L Duratec (147kW/200PS) - VI5 –Component Location
E105870
1
2
3
4
5
6
7
8
10
9
11
Description
Item
Fuel pump and level indicator module,
right-hand side
1
EVAP (evaporative emission) extraction
points
2
Fuel pump and lines for the fuel-fired
booster heater/additional heater
3Description
Item
Fuel-filler pipe
4
EVAP container and lines
5
Vent hose, fuel filler pipe
6
Fuel pump and level indicator module,
left-hand side
7
Fuel tank
8
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310-01- 2
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Description
Item
Fuel tank retaining straps
9Description
Item
Line, fuel tank to fuel distribution pipe
10
Connection, fuel-fired booster
heater/additional heater
11
E105871
1
2
3
4
5
6
Description
Item
Fuel-filler pipe
1
Fuel filler opening, capless
2
Vent hose, fuel filler pipe
3Description
Item
Overflow hose, fuel filler pipe
4
EVAP venting/breather hose
5
Fuel pump and lines for the fuel-fired
booster heater/additional heater
6
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E105872
1
2
4
5
6
7
10
8
11
3
9
Description
Item
Fuel pump and level indicator module,
left-hand side
1
Seal, fuel pump and level indicator
module, left-hand side
2
Retaining ring, fuel pump and level
indicator module, left-hand side
3
Nut, fuel pump and level indicator module,
left-hand side
4
Float, fuel pump and level indicator
module, left-hand side
5Description
Item
Suction hose, left-hand half of the fuel tank
6
Fuel pump and level indicator module,
right-hand side
7
Nut, fuel pump and level indicator module,
right-hand side
8
Retaining ring, fuel pump and level
indicator module, right-hand side
9
Seal, fuel pump and level indicator
module, right-hand side
10
Float, fuel pump and level indicator
module, right-hand side
11
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310-01-
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310-01- 4
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Fuel Tank and Lines — 2.5L Duratec (147kW/200PS) - VI5 –Overview
Fuel tank
The fuel tank is the same on vehicles with FWD
and AWD. The fuel tank is saddle-shaped to accommodate the drive shaft and the exhaust
system. Depending on the design, the volume of
the tank is 56 liters or 66 liters.
Fuel pump and sender unit
E106247
12
Description
Item
Fuel pump and level indicator module,
left-hand side
Comments:Inactive side without separate fuel pump
1
Fuel pump and level indicator module,
right-hand side
2
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310-01-
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Changing the right-hand fuel pump and level
indicator module
E113328
If the right-hand fuel pump and level indicator
module needs to be changed on a vehicle with a
booster heater/additional heater, the bore for the
connection to the fuel-fired booster
heater/additional heater must be drilled.
The right-hand fuel pump and level indicator
module contains a demand-switched electric fuel
pump which drives two suction jet pumps. One of
them ensures that fuel is pumped from the left-hand
half of the tank into the right-hand half. On-demand
switching is performed by the fuel pump module.
To remove the right-hand fuel pump and level
indicator module it is necessary to detach theleft-hand fuel pump and level indicator module and
pull it out slightly so that the connecting hose can
be detached and the connector for the left-hand
fuel pump and level indicator module can be
disconnected. The left-hand fuel pump and level
indicator module can be removed without detaching
the right-hand fuel pump and level indicator
module.
The instrument cluster uses the signals from both
fuel fill level sensors to determine the fuel fill level.
The resistor tracks of the fuel fill level sensors
cannot be replaced individually.
The fuel filter is designed to last for the service life
of the vehicle and does not need to be replaced.
The right-hand fuel pump and level indicator
module contains an overpressure limiting valve.
This overpressure limiting valve ensures that the
fuel pressure between the injectors and the
right-hand fuel pump and level indicator module
does not exceed 3.3 bar after the engine is
stopped. This reduces the formation of vapor
bubbles and also prevents dripping from the
injectors.
Fuel filler pipe and tank cap
NOTE:
Any water in the filling area can cause the
mechanism to freeze at temperatures below 0 °C.
In this case the closing mechanism will not open
when the nozzle of the petrol/diesel pump is
inserted.
43
1
2
1
5
43
1
2
1
5
E100648
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Description
Item
Latch mechanism
1
Housing, capless fuel filler pipe
2
Overflow
3Description
Item
Gasket
4
Filler nozzle
5
A spring-loaded fuel filler door closes off the upper
end of the fuel tank filler pipe in place of the filler
cap. The spring-loaded fuel filler door features a
latching mechanism. The release mechanism is
matched to the size of the filler nozzle. If the correct
filler nozzle is inserted, the release lugs are pushed
back. This releases the slide which can move
upwards and opens the way to the spring-loaded
fuel filler door for the filler nozzle.
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310-01- 7
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310-01- 7
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Fuel Tank — 2.5L Duratec (147kW/200PS) - VI5
Removal
WARNING: Avoid flames, sparks or lighted
substances.
NOTE: Removal steps in this procedure may
contain installation details.
1. Refer to: Battery Disconnect and Connect
(414-01 Battery, Mounting and Cables,
General Procedures).
4x4
2. Refer to: Driveshaft (205-01 Driveshaft,
Removal and Installation).
All vehicles
3. Torque: 48Nm
x2x2
E104225
4.
E104226
5.Torque: 15Nm
E113922
x2
6.Torque: 15Nm
x4x4
E113923
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310-01- 8
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310-01- 8
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7.Torque: 15Nm
x4x4
E104227
8.Refer to: Fuel Tank Draining (310-00 Fuel
System - General Information, General
Procedures).
Vehicles with fuel fired booster heater
9.
E113924
10.
E113925
11. WARNING: Be prepared to collect escaping fluids.
CAUTION: Use suitable paper to absorb
any escaping fluid.
Refer to: Quick Release Coupling (310-00 Fuel
System - General Information, General
Procedures).
x2x2
E113944
All vehicles
12. WARNING: Be prepared to collect escaping fluids.
CAUTION: Use suitable paper to absorb
any escaping fluid.
Refer to: Quick Release Coupling (310-00 Fuel
System - General Information, General
Procedures).
E113945
13. Torque: 30Nm
x4x4
E104228
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310-01- 9
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310-01- 9
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14.
E104859
x2
15. WARNING: Be prepared to collectescaping fluids.
CAUTION: Use suitable paper to absorb
any escaping fluid.
x2x2
E113946
16.
E104642
x2
Vehicles with fuel fired booster heater
NOTE:This step is only necessary when installing
a new component.
17. WARNING: Be prepared to collect escaping fluids.
CAUTION: Use suitable paper to absorb
any escaping fluid.
Refer to: Quick Release Coupling (310-00 Fuel
System - General Information, General
Procedures).
E113927
All vehicles
NOTE: This step is only necessary when installing
a new component.
18. Refer to: Fuel Pump and Sender Unit - 2.5L
Duratec (147kW/200PS) - VI5 (310-01 Fuel
Tank and Lines, Removal and Installation).
Installation
1. To install, reverse the removal procedure.
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310-01- 10
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