Attachment III - Technical Information
OVERVIEWThis program involves replacing the fuel delivery module (FDM) with a new, redesigned module.
A redesigned fuel filter inlet tube is also being installed due to the FDM design changes.
The new module is top-mounted in the tank and requires the removal of the retaining ring that attaches the original FDM to the floor of the tank.
A special cut-off tool, 310-133. has been designed to cut the tabs of the retaining ring without damaging the fuel tank vapor barrier (inside surface of the tank). Each dealer will receive one special cut-off tool and two sample retaining rings. The rings are provided so the technicians can practice fitting the tool and cutting the tabs before performing the repair on a customer's vehicle.
VIDEO TRAINING MATERIAL INFORMATION
An 8-minute training video has been produced demonstrating the proper use of the special cut-off tool and installation of the new fuel delivery module. It is available for viewing on Ford star and the PTS website.
It is strongly suggested that you view the video prior to performing the first repair on a customer's vehicle.
FUEL TANK AND FUEL DELIVERY MODULE REMOVAL
1. Remove and discard the fuel delivery module from the fuel tank. Refer to Section 310-01 of either the 2000 or 2001 model year Workshop Manual for removal instructions, including depressurizing the fuel system and draining the tank.
CAUTION:
The fuel tanker used to store the removed fuel must be equipped with a filtering system. Rotunda Fuel Tankers, such as model 034-00014 or 034-00004 (shown in the illustration) are equipped with the necessary filtering systems.
NOTE:
Use Rotunda 5' Adapter Hose, 034-R0077, attached to the end of the fuel tanker drain hose to drain the vehicle fuel tank. To enable the adapter hose to enter the tank, a 40-mm long taper must be cut in the end of the hose.
CUT-OFF TOOL INFORMATION
FDM RETAINING RING REMOVAL
FUEL DELIVERY MODULE (FDM) INSTALLATION
CAUTION:
If you have not removed the retaining ring as previously described, you cannot properly install the new FDM.
1. Install the new gasket onto the new FDM. Be sure it sits flat on the underside of the flange and that it is not rolled or twisted.
2. NOTE: The new FDM has a spring-loaded upper plate which must be pushed and held downward to install the locking ring.
^ Position the new FDM into the fuel tank.
^ Place the locking ring over one hand (like a bracelet).
^ With that same hand, push the FDM upper plate down while aligning the two locating tabs on the FDM with the two (2) notches on the fuel tank.
^ While holding the upper plate in place, use your other hand to install and tighten the FDM locking ring.
^ Using Fuel Tank Wrench 310-069, tighten the FDM locking ring to 80 Nm (59 lb-ft).
3. Install the new fuel filter inlet tube assembly onto the FDM.
NOTE:
The new FDM will be shipped with either a shipping plug or tape covering the red connector. This is to prevent dirt or contaminants from entering the FDM prior to installation. Remove only the shipping plug or tape. DO NOT REMOVE THE RED CONNECTOR!!!
FUEL TANK INSTALLATION
1. Reinstall the fuel tank as outlined in the appropriate workshop manual.
2. Replace the drained and filtered fuel.
3. Perform an Evaporative Emissions System Leak Test as follows:
CAUTION:
The evaporative emission system must not be pressurized to more than 3.48 kPa (14 inches H20) or damage to the evaporative emission system may occur.
a) Connect the Evaporative Emission System Leak Tester 310-F007 (134-00056 or equivalent) to the evaporative test port.
b) NOTE: The ignition switch must be in the key ON/Engine OFF position. Using WDS, NGS or equivalent, apply 12 volts to the canister vent solenoid.
c) Pressurize the evaporative emissions system to 3.48 kPa (14 inches H20).
d) Monitor the system for two (2) minutes. If pressure falls below 2.0 kPa (8 inches H20), the system has failed the leak test.
e) Repair any leaks necessary. (NOTE: Any repairs not related directly to the FDM replacement are not covered by this program.)
f) Repeat the Evaporative Emissions System Leak Test until the system remains above 2.0 kPa (8 inches H20) after the last test period.
4. Perform a post-repair road test to determine that the driveability concern has been corrected.