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FUEL SYSTEM DESCRIPTION Fuel is drawn by the supply pump through a pre-filter screen in the tank and to the engine through the fuel supply lines. There is no lift pump in the fuel tanks or on the frame. The fuel passes through the base plate of the fuel injector control module (FICM) to cool the module. From the FICM the fuel flows to the fuel filter/heater element housing, which combines a water separator, a prime pump, a fuel heater element and a filter element. The fuel is then delivered to the high-pressure pump. An integrated hand pump is used to prime the fuel system after changing the fuel filter or servicing the fuel system. The fuel injection pump at the front of the engine valley includes the fuel supply pump and the high-pressure pump. If the fuel system is not suppling enough fuel, a driveability concern may occur. If air is being drawn into the fuel injection system, a Cranks But Will Not Run or Hart Start symptom could exist. HIGH PRESSURE SYSTEM The much larger section of the pump assembly is the high-pressure fuel injection pump. The pump is engine-driven by the camshaft gear. From the high-pressure pump, the pressurized flows to the left common fuel rail. A balance pipe from the center of the left rail then feeds the right common fuel rail. Each common fuel rail supplies one bank of 4 fuel injectors. The fuel rail pressure sensor is mounted in the middle of the right common fuel rail. RETURN SYSTEM The fuel return system routes fuel from the fuel injectors and the fuel injection pump. The fuel rail pressure relief valve is located in the rear of the left common rail. The return fuel travels to the fuel cooler and then to the fuel tank. This fuel is used to cool and lubricate the injection pump and the injectors. DIAGNOSTIC AIDS The following conditions may cause an air leak into the fuel supply system: Deformed or cut O-rings at the fuel supply line connections Improperly seated fuel supply line fittings Porous or weathered rubber fuel supply lines

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1. Drain engine cooling system. Refer to Section 03-03. 2. Remove upper radiator sight shield (8C291). 3. Disconnect radiator overflow hose (8075) from radiator (8005). Remove bolts retaining coolant recovery reservoir (8A080) and bracket to radiator support. Disconnect coolant recovery reservoir from lower locator and remove coolant recovery reservoir. 4. Remove cooling fan motor, fan blade (8600) and fan shroud (8146) assembly as described in Section 03-03. 5. Rotate drive belt tensioner (6B209) . Remove drive belt (8620) . Refer to Section 03-05. 6. Remove retaining bolts and water pump pulley (8509) . 7. Remove power steering pump pulley (3A733) and remove water pump-to-power steering pump brace. 8. Remove bolt and nuts retaining ignition coil (12029) and bracket. Position out of the way. 9. Remove heater water outlet tube retaining bolts and heater water outlet tube (18663) from water pump (8501) . 10. Disconnect lower radiator hose (8286) from water pump . 11. CAUTION: If using a prying device to assist in water pump removal, be careful not to damage the mating surfaces. Remove water pump retaining bolts, stud bolts and nuts. Remove water pump . Discard old water pump housing gasket (8507) . Installation 1. NOTE: Lightly oil all bolt and stud threads before installation except those specifying special sealant with SAE 5W-30 Super Premium Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Clean gasket surfaces on water pump and engine front cover (6019) . 2. NOTE: Gasket and Trim Adhesive F3AZ-19B508-B or equivalent meeting Ford specifications ESR-M11P17 and ESE-M2G52-A is recommended to hold the water pump housing gasket in position. Position a new water pump housing gasket on water pump sealing surface. 3. NOTE: The threads of the No. 1 water pump retaining bolt must be coated with Pipe Sealant with Teflon® D8AZ-19554-A or equivalent meeting Ford specifications WSK- M2G350-A2 and ESR-M18P7-A before installing. Position water pump on the engine front cover . Install retaining bolts, stud bolts and nuts. Tighten retaining bolts and studs to 20-30 Nm (15-22 lb-ft). Tighten retaining nuts to 8-12 Nm (71-106 lb-in). 4. Inspect O-ring (replace as necessary) and install heater water outlet tube to water pump . Tighten retaining bolts to 8-12 Nm (71-106 lb-in). 5. Position coil and bracket assembly. Tighten retainers to 25 Nm (18 lb-ft). 6. Install lower radiator hose to water pump . Tighten clamps securely. 7. Install water pump-to-power steering pump brace and install water pump pulley .

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Water Pump Removal 1. Drain the cooling system. Refer to Section 03-03. 2. Disconnect the battery ground cable (14301) . 3. Remove the generator drive belt, water pump and power steering pump drive belt, and the A/C compressor drive belt (if equipped). Refer to Section 03-05. 4. Raise and support the vehicle. 5. Use Strap Wrench D85L-6000-A or equivalent to hold the water pump pulley (8509) while removing the four water pump pulley bolts. 6. Remove the water pump pulley from the water pump (8501) . 7. Remove the crankshaft pulley (6312) . Refer to the procedure in this section 8. Remove the five lower engine front cover bolts and the lower engine front cover (6019) . NOTE: Make a note of the location of the one water pump bolt with the threads in the bolt head for ease of installation. 9. Remove the six water pump bolts. 10. Remove the water pump . Installation NOTE: Ensure the mating surfaces between the water pump and the cylinder block (6010) are cleaned of any sealant material. 1. Install a continuous 2.0-3.0mm (0.079-0.118 inch) wide bead of Gasket Maker E2AZ-19562-B or equivalent meeting Ford specification WSK-M2G348-A5, on the water pump and position the water pump on the cylinder block . NOTE: Refer to the note made during removal for the location of the bolt with the threads in the bolt head. 2. Install the six water pump bolts. Tighten the water pump bolts to 16-21 Nm (12-15 lb-ft). 3. Install the crankshaft pulley . Refer to the procedure in this section. 4. Position the water pump pulley on the water pump and install the four water pump pulley bolts. 5. Use Strap Wrench D85L-6000-A or equivalent to hold the water pump pulley , and tighten the four water pump pulley bolts to 16-21 Nm (12-15 lb-ft). 6. Install the lower engine front cover and the five lower engine front cover bolts. Tighten the five lower engine front cover bolts to 3-5 Nm (27-44 lb-in). 7. Lower the vehicle. 8. Install and adjust the generator drive belt, water pump and power steering pump drive belt, and the A/C compressor drive belt (if equipped). Refer to Section 03-05. 9. Connect the battery ground cable . 10. Fill the cooling system. Refer to Section 03-03. 11. Start the engine (6007) and check for leaks.

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1. Drain the cooling system. Refer to Section 03-03 for the procedure. 2. Disconnect the battery ground cable (14301) . 3. Remove the generator drive belt, water pump and power steering pump drive belt, and the A/C compressor drive belt (if equipped). Refer to Section 03-05 for the removal procedures. 4. Raise and support the vehicle. 5. Use Strap Wrench D85L-6000-A or equivalent to hold the water pump pulley (8509) while removing the four water pump pulley bolts. 6. Remove the water pump pulley from the water pump (8501) . 7. Remove the crankshaft pulley (6312) . Refer to the procedure in this section 8. Remove the five lower engine front cover bolts and the lower engine front cover (6019) . 9. NOTE: Make a note of the location of the one water pump stud/bolt for ease of installation. Remove the six water pump bolts. 10. Remove the water pump . Installation 1. NOTE: Ensure the mating surfaces between the water pump and the cylinder block (6010) are cleaned of any sealant material. Install a continuous 2.0-3.0mm (0.079-0.118 inch) wide bead of Gasket Maker E2AZ-19562-B or equivalent meeting Ford specification WSK-M2G348-A5, on the water pump and position the water pump on the cylinder block . 2. NOTE: Refer to the note made during removal for the location of the stud/bolt. Install the six water pump bolts. Tighten the water pump bolts to 16-21 Nm (12-15 lb-ft). 3. Position the water pump pulley on the water pump and install the four water pump pulley bolts. 4. Use Strap Wrench D85L-6000-A or equivalent to hold the water pump pulley , and tighten the four water pump pulley bolts to 16-21 Nm (12-15 lb-ft). 5. Install the lower engine front cover and the five lower engine front cover bolts. Tighten the five lower engine front cover bolts to 3-5 Nm (27-44 lb-in). 6. Install the crankshaft pulley . Refer to the procedure in this section. 7. Lower the vehicle. 8. Install and adjust the generator drive belt, water pump and power steering pump drive belt, and the A/C compressor drive belt (if equipped). Refer to Section 03-05 for the installation and adjustment procedures. 9. Connect the battery ground cable . 10. Fill the cooling system. Refer to Section 03-03 for the procedure. 11. Start the engine (6007) and check for leaks.

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Removal 1. Remove fuel tank (9002) as described. 2. Remove any dirt that has accumulated around fuel pump module retaining flange. 3. Turn fuel pump module locking retainer ring counterclockwise using Fuel Tank Sender Wrench 310-002 (T74P-9275-A) and remove fuel pump module locking retainer ring. 4. Pull fuel pump module sender plate up out of fuel tank until locking tabs for fuel pump module are accessible. Reach through fuel pump module opening, squeeze both locking tabs together and remove fuel pump module from fuel tank . 5. Remove O-ring seal and discard. Installation 1. Clean fuel pump module retaining flange, fuel tank mounting surface and seal ring groove. 2. Apply a light coating of Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-BA on a new O-ring seal to hold it in place during assembly and install O-ring in seal ring groove. 3. Install fuel pump module carefully into fuel tank to make sure that filter, hoses and float rod are not damaged or binding. Align fuel pump module and fuel tank retainer and push fuel pump module into fuel tank retainer. A definite click will be heard when the two tabs on fuel pump module engage the fuel tank retainer. The fuel pump module must be snapped in the retainer with both tabs. Pull on fuel pump module to make sure it is fully engaged. Install fuel pump module sender plate to fuel tank , being careful that locating keys are in keyways and O-ring seal remains in place. 4. Hold assembly in place and install fuel pump module locking retainer ring finger-tight. Make sure that all locking tabs are under fuel pump module locking retainer ring tabs. 5. Secure fuel pump module unit by rotating fuel pump module locking retainer ring clockwise using Fuel Tank Sender Wrench 310-002 (T74P-9275-A) until fuel pump module locking retainer ring contacts the stops. 6. Install fuel tank in vehicle as described. 7. Lower vehicle. 8. Install a minimum of 38 liters (10 gallons) of fuel. Check for leaks. 9. Turn ignition switch to RUN position for three seconds repeatedly (5 to 10 times) until Multiport Fuel Injection (MFI) Fuel Pressure Gauge 310-012 (T80L-9974-B) or equivalent (depending upon application) shows at least 207 kPa (30 psi). Check for leaks at fittings. 10. Remove Multiport Fuel Injection (MFI) Fuel Pressure Gauge 310-012 (T80L-9974-B) or equivalent (depending upon application), start engine and recheck for leaks.