Fuel Tank and Lines
Fuel Delivery Module
The fuel delivery module is a new design for 2006MY vehicles. The module is located inside the fuel tank and comprises three main components; a fuel pump, a remote jet pump and a top flange assembly.
Fuel Pump
The fuel pump is a dual stage electric pump which is located in the bottom of the fuel tank, on the right hand side. The fuel pump delivers fuel at a maximum pressure of 5.0 bar (72.5 lbf/Sq.in) to the filter bowl in the top flange.
The pump has a spring loaded top plate which secures the pump by compression in its location in the front right hand side of the fuel tank. The electric pump is located in a plastic swirl pot which collects fuel from the base of the fuel tank via a filter.
The fuel level sensor the right hand side of the tank is attached to the outside of the swirl pot.
The fuel pump is a serviceable component. Access to the pump is by removal of the top flange.
Remote Jet Pump
The remote jet pump is located in the front left hand side of the fuel tank. The jet pump has a spring loaded frame which secures the pump by compression in the fuel tank.
The jet pump is connected by two pipes to the fuel pump. One small diameter pipe supplies pressurized fuel from the fuel pump to the jet pump. The jet pump is also connected to the fuel pump swirl pot by a larger diameter pipe. The pressurized fuel from the small pipe enters the larger pipe and the fuel flow causes a vacuum which draws fuel from the bottom of the tank via a filter. This fuel, collected from the left hand side of the fuel tank, in addition to the pressurized fuel from the fuel pump is delivered back to the fuel pump swirl pot in the right hand side of the tank.
The fuel level sensor for the left hand side of the fuel tank is attached to the remote jet pump frame.
The remote jet pump is a serviceable component. Access to the jet pump is by removal of the flange cover on the top left hand side of the fuel tank.
Top Flange Assembly
The top flange is located on the top right hand side of the fuel tank. The flange assembly is sealed in the tank with a with a sealing ring. A locking ring secures the flange assembly in the tank and requires a special tool for removal.
The outer surface of the flange has two outlets with quick-fit connections. One connection is the pressure outlet to the fuel rail, the second outlet is the fuel supply to the Fuel Fired Booster Heater (FFBH) pump, if fitted.
An electrical connector is located adjacent to the pipe connections and provides the electrical interface to the fuel pump and the level sensors.
On the underside of the flange, inside the tank, is a moulded housing which contains the fuel filter. Fuel from the fuel pump enters the base of the housing and passes through the filter before exiting the tank to the fuel rail or the FFBH pump, if fitted. An electrical connection on the base of the filter housing provides a ground for the filter.