310-00C Fuel System - General Information - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS) 2016 Mustang

310-00C Fuel System - General Information - 5.0L 32V Ti-VCT/5.
0L 2016 Mustang
Ti-VCT V8 (308kW/418PS)
Procedure revision date:
Specifications 06/27/2014
Specifications
General Specifications
Item Specification
Fuel Pressure
Engine running - 2.3L GTDi (Low pressure side) 50.8–75.4 psi (350–520 kPa)
Engine running - 3.7L Duratec, 5.0L Ti-VCT 53.1–63.1 psi (366–435 kPa)
Fuel Tank Capacity
Fuel Tank Capacity - 2.3L GTDi 15.5 gal (58.67 L)
Fuel Tank Capacity - 3.7L Duratec, 5.0L Ti-VCT 16.0 gal (60.55 L)
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Copyright © 2016 Ford Motor Company
310-00C Fuel System - General Information - 5.0L 32V Ti-VCT/5.0L 2016 Mustang
Description and Operation 06/27/2014
Fuel System - Overview
Overview
The fuel system consists of the :
saddle-type fuel tank.

quick connect fuel and vapor tube couplings.
has a supplemental refueling adapter located in the luggage compartment.
fuel tank filler pipe assembly, which cannot be modified in any way, that also contains a restrictor plate to
permit only unleaded fuel to be pumped into the tank.
has an Easy Fuel™ (capless) fuel tank filler pipe assembly, which cannot be modified in any way and is
serviced only by the installation of a new fuel tank filler pipe assembly.
has a Fuel Pump Control Module located under the rear seat cushion LH side of the vehicle.
fuel rail.
fuel injectors.
Fuel Tank Pressure (FTP) sensor (part of the fuel vapor tube assembly).
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Mechanical Returnless Fuel System (MRFS).
Fuel Level Sensor
Fuel Pump (FP) module containing:
The electric FP module which provides pressurized fuel to the high pressure Fuel Pump (FP) .
The Fuel Level Sender.
A check valve which maintains system pressure after the pump is shut off.
A pressure relief for overpressure protection in the event of restricted fluid flow.
A lifetime fuel filter providing filtration to protect the fuel injectors from foreign material.
Fuel Pump Shut-off Feature
In the event of a moderate to severe collision, the vehicle is equipped with a Fuel Pump and Sender Unit Shut-off
Feature that is initiated by the event notification signal.
The event notification signal is a signal provided by the RCM to the Fuel Pump Control Module. Signal
communication between the RCM and the Fuel Pump Control Module allows the PCM to shut-off the Fuel Pump.
Should the vehicle shut off after a collision due to this feature, the vehicle may be restarted by first turning the
ignition to the OFF position and then turn the ignition to the ON position. In some instances the vehicle may not
start the first time and may take one additional ignition cycle.

Diagnosis and Testing 10/22/2015
Fuel System
Symptom Chart(s)
Symptom Chart: Fuel System
Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).
for information regarding Ford-specific diagnostic practices.
NOTE: The following procedure diagnoses a slow to fill concern only. For all other concerns, refer to Refer to
Powertrain Control/Emissions Diagnosis (PC/ED) manual.
Symptom Chart
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Condition Possible Sources Actions
Slow to fill Fuel tank filler pipe Refer to GO to Pinpoint Test A
Fuel tank filler pipe vent tube, if
equipped
EVAPsystem
Fuel tank inlet check valve (part
of the fuel tank)
Fuel level vent valve (part of the
fuel tank)
All other fuel system Fuel system components Refer to Powertrain Control/Emissions
concerns Diagnosis (PC/ED) manual.
Diagnostic Routine(s)
Slow to Fill
Normal Operation and Fault Conditions
Under normal operation, fuel should flow at a steady rate through the fuel tank filler pipe into the fuel tank. As fuel
enters the fuel tank air is vented through the filler pipe or the ORVR system.
PINPOINT TEST A : SLOW TO FILL

A1 CHECK COMPONENTS FOR SIGNS OF DAMAGE
Visually inspect the following components for signs of damage:
Fuel tank filler pipe
Fuel tank filler pipe vent tube, if equipped
EVAP system
Fuel tank inlet check valve (part of the fuel tank)
Fuel level vent valve (part of the fuel tank)
Was the cause of the concern found?
Yes REPAIR or INSTALL new components to correct the concern.

No GO to A2
A2 CHECK THE SYSTEM FOR ANY EVAP (EVAPORATIVE EMISSION) DTC'S

Connect the scan tool.
Check the system for any EVAP DTC's.
Are any DTC's present?
Yes Refer to Powertrain Control/Emissions Diagnosis (PC/ED) manual.

No GO to A3
A3 MONITOR THE FTP WHILE FILLING THE FUEL TANK

NOTE: During normal fuel fill the Fuel Tank Pressure (FTP) Sensor value starts at 2.6 volts and will
increase .3 to .7 of a volt from its starting point.
Monitor the Fuel Tank Pressure (FTP) reference value while filling the fuel tank. Refer to the Reference
Values in the Powertrain Control/Emissions Diagnosis (PC/ED) manual. Refer to Powertrain
Control/Emissions Diagnosis (PC/ED) manual.
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Is FTP within specification?
Yes GO to A5
No GO to A4
A4 MONITOR THE FTP WHILE FILLING THE FUEL TANK WITH THE EVAP SYSTEM
DISCONNECTED
Disconnect the fuel tank-to-EVAP canister quick connect coupling at the EVAP canister.
NOTE: During normal fuel fill the Fuel Tank Pressure (FTP) Sensor value starts at 2.6 volts and will
increase .3 to .7 of a volt from its starting point.
Monitor the FTP reference value while filling the fuel tank. Refer to Powertrain Control/Emissions
Diagnosis (PC/ED) manual.
Is FTP within specification?
Yes INSPECT the EVAP system for blockage or restrictions. REPAIR the blockage or
restriction. If the blockage or restriction cannot be repaired, INSTALL new EVAP system
components.
No GO to A5
A5 CHECK THE FUEL TANK FILLER PIPE ASSEMBLY FOR BLOCKAGE OR RESTRICTION
Remove the fuel tank filler pipe assembly.
REFER to: Fuel Tank Filler Pipe (310-01C Fuel Tank and Lines - 5.0L 32V Ti-VCT, Removal and
Installation).
Inspect the fuel tank filler pipe and fuel tank filler pipe vent tube (if equipped) for a blockage or restriction.
Is the fuel tank filler pipe or fuel tank filler pipe vent tube (if equipped) blocked or restricted?
Yes If possible, REPAIR the blockage or restriction. If the blockage or restriction cannot be
repaired, INSTALL a new fuel tank filler pipe or fuel tank filler pipe vent tube.
No GO to A6
A6 CHECK THE FUEL TANK INLET CHECK VALVE

Inspect the fuel tank inlet check valve for restriction or sticking.
Is the fuel tank inlet check valve restricted or sticking?
Yes If possible, REPAIR the restriction. If the restriction cannot be repaired, INSTALL a new
fuel tank.
REFER to: Fuel Tank (310-01C Fuel Tank and Lines - 5.0L 32V Ti-VCT, Removal and
Installation).
No INSTALL a new fuel tank.
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General Procedures 06/16/2015
Fuel System Pressure Check
Special Tool(s) / General Equipment
310-D009 (D95L-7211-A)
Fuel Pressure Test Kit
Check
NOTE: This Fuel System Pressure Check is for the low pressure side of the system.
1. Release the fuel system pressure.

Refer to: Fuel System Pressure Release (310-00C Fuel System - General Information - 5.0L 32V
Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS), General Procedures).
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2. Disconnect the battery ground cable.
Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
3. Disconnect the fuel jumper tube-to-fuel rail quick release coupling.

Refer to: Quick Release Coupling (310-00C Fuel System - General Information - 5.0L 32V Ti-VCT/5.0L
Ti-VCT V8 (308kW/418PS), General Procedures).
4. Install the Fuel Pressure Test Kit between the fuel jumper tube and the fuel rail.
Use Special Service Tool: 310-D009 (D95L-7211-A) Fuel Pressure Test Kit.
5. NOTE: The FPDM electrical connector was previously disconnected to release the fuel system pressure
and must be reconnected to test the fuel system pressure.
Reconnect the FPDM electrical connector.

6. Connect the battery ground cable.
7. NOTE: Carry out a Key ON Engine OFF (KOEO) visual inspection for fuel leaks prior to completing the
fuel system pressure test.
Test the fuel system pressure to make sure it is within the specified range. For additional information, refer
to Specifications in this section.
8. After completion of the fuel system pressure test, disconnect the battery ground cable, open the drain
valve on the Fuel Pressure Test Kit and release any residual fluid into an appropriate container.
9. Remove the Fuel Pressure Test Kit by reversing the installation steps.
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Fuel Tank Draining
292-00004
Fuel Tanker 100 GPM
310-123
Locking Ring, Fuel Tank
TKIT-2004J-F
TKIT-2005U-LM
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Draining
1. Release the fuel system pressure.


3. NOTE: The supplemental refueling adapter is located in the luggage compartment.
Install the supplemental refueling adapter and a 6 ft. length of 5/8 in. semi-rigid fuel drain tube into the Easy
Fuel™ (capless) fuel tank filler pipe until the tube enters the fuel tank.
4. NOTE: This step is to remove approximately 3/16 tank of the fuel (3 gallons) from a completely full fuel
tank and the majority of any residual fuel in the fuel tank filler pipe, lowering the fuel level below the Fuel
Pump and Sender Unit mounting flange.
Attach the Fuel Storage Tanker to the fuel drain tube and remove as much fuel as possible from the tank.
Use Special Service Tool: 292-00004 Fuel Tanker 100 GPM.
5. Remove the rear seat cushion.

Refer to: Rear Seat Cushion (501-10B Rear Seats, Removal and Installation).
6. Remove the access cover and position aside.
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7. Disconnect electrical connector and fuel tube quick release coupling.
Refer to: Quick Release Coupling (310-00C Fuel System - General Information - 5.0L 32V Ti-VCT/5.0L
Ti-VCT V8 (308kW/418PS), General Procedures).
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8. NOTICE: Carefully install the Fuel Tank Sender Unit lock ring wrench to avoid damage to the Fuel
Pump and Sender Unit when removing the lock ring.
Using the special tool remove the Fuel Pump and Sender Unit lock ring.
Use Special Service Tool: 310-123 Locking Ring, Fuel Tank.
9. NOTICE: The Fuel Pump and Sender Unit must be handled carefully to avoid damage to the float
arm.
Position the Fuel Pump and Sender Unit aside. Using the Fuel Storage Tanker, completely drain the
remaining fuel from the LH saddle of the fuel tank.
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10. NOTE: Inspect the surfaces of the Fuel Pump and Sender Unit flange and fuel tank O-ring seal contact
surfaces. Do not polish or adjust the O-ring seal contact area of the fuel tank flange or the fuel tank.
Install a new Fuel Pump and Sender Unit or fuel tank if the O-ring seal contact area is bent, scratched or
corroded.
Remove and discard the O-ring seal.
11. Remove the access cover and position aside.
12. NOTE: Clean the fuel level sensor connections, flange surfaces and the immediate surrounding area of
any dirt or foreign material.
Disconnect the electrical connector.

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13. NOTICE: Carefully install the Fuel Tank Sender Unit lock ring wrench to avoid damage to the fuel
level sensor when removing the lock ring.
Using the special tool remove the fuel level sensor lock ring.
Use Special Service Tool: 310-123 Locking Ring, Fuel Tank.
14. NOTICE: The fuel level sensor must be handled carefully to avoid damage to the float arm.
Position the fuel level sensor aside. Using the Fuel Storage Tanker, completely drain the RH saddle of the
fuel tank.
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15. NOTE: Inspect the surfaces of the Fuel Level Sensor flange and fuel tank O-ring seal contact surfaces.
Do not polish or adjust the O-ring seal contact area of the fuel tank flange or the fuel tank. Install a new
Fuel Level Sensor or fuel tank if the O-ring seal contact area is bent, scratched or corroded.
Remove and discard the Fuel Level Sensor O-ring seal.

Quick Release Coupling
Disconnect
NOTICE: When reusing liquid or vapor tube connections, make sure to use compressed air to remove
any foreign material from the connector retaining clip area before separating from the tube or damage to
the tube or connector retaining clip may occur.
NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is
essential that absolute cleanliness is observed when working with these components or component
damage may occur. Always install blanking plugs to any open orifices or tubes.
NOTICE: Do not use any tools. The use of tools may cause a deformity in the clip components which may
cause fuel leaks.
NOTE: Type 1
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1. If servicing a liquid fuel tube quick connect coupling, release the fuel system pressure.

3.
4.
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Connect
1. Inspect and clean both quick coupling ends.
2. NOTE: Make sure the retainer clip is fully seated and locked onto the tube by pulling on the quick
connect coupling.
Press the retainer clip into the quick connect coupling body until flush and the tabs are locked in place.
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Disconnect
cause fuel leaks.
NOTE: Type 2

3.
1.
4.
Connect
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2.

Disconnect
cause fuel leaks.
NOTE: Type 3

3.
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Connect
1.
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2.

Disconnect
cause fuel leaks.
NOTE: Type 4

3.
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4.
Connect
1.
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Disconnect
NOTICE: When reusing liquid tube connectors, make sure to use compressed air to remove any foreign
material from the connector retaining clip area before separating from the tube or damage to the tube or
connector retaining clip may occur.
cause fuel leaks.
NOTE: Type 5

3.
1.
4.
Connect
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Disconnect
NOTICE: When reusing liquid tube connectors, make sure to use compressed air to remove any foreign
material from the connector retaining clip area before separating from the tube or damage to the tube or
connector retaining clip may occur.
cause fuel leaks.
NOTE: Type 8

3. 1. Release the secondary locking tab.

2. Depress the primary locking tab.
3. Separate the quick release coupling from the tube.
Connect
1. 1. Push the quick release coupling onto the tube.
2. NOTE: Pull on the quick release coupling and the fitting to make sure it is securely fastened.
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Lock the secondary locking tab.


Spring Lock Couplings
310-S039 (T90T-9550-S)
Disconnect Tool, Spring Lock Coupling
TKIT-1990-LMH
Disconnect
NOTICE: When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any
foreign material from the connector retaining clip area before separating from the tube or damage to the
tube or connector retaining clip can occur. Apply clean engine oil to the end of the tube before inserting
the tube into the connector.
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damage can occur. Always install plugs to any open orifices or tubes.
1. If servicing a liquid fuel tube spring lock coupling, release the fuel system pressure.

3. If equipped, remove the fuel tube safety clip.
4. Install the Spring Lock Coupling Disconnect Tool on the tube and push into the spring lock coupling to
release.
Use Special Service Tool: 310-S039 (T90T-9550-S) Disconnect Tool, Spring Lock Coupling.
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5. Separate the spring lock coupling from the tube.
Connect
1. Align and push the spring lock coupling onto the tube until fully seated.
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2. If equipped, install the fuel tube safety clip.
3. Pull on the coupling to make sure it is fully engaged.


Fuel System Pressure Release
Pressure release
NOTE: The FPDM is located on the LH side, beneath the rear seat cushion.
1. Remove the rear seat cushion.

2. NOTE: On vehicles equipped with Gasoline Turbocharged Direct Injection (GTDI), running the engine
with the FPDM disconnected will remove most of the pressure from both the low and high pressure sides
of the system.
Disconnect the FPDM electrical connector.
3. Start the engine and allow it to idle until the engine stalls.
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4. Turn the ignition switch to the off position.
5. When the fuel system service is complete, reconnect the FPDM electrical connector.
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6. Install the rear seat cushion.
7. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the
engine.
8. When service on the fuel system is complete, start the engine and check for leaks.

310-00C Fuel System - General Information - 5.0L 32V Ti-VCT/5.0L Ti-VCT V8 (308kW/418PS) 2016 Mustang

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What are the components of the fuel system?

What are the components of the fuel system?

What is the purpose of the fuel pump shut-off feature?

What is the purpose of the fuel pump shut-off feature?

310-00C Fuel System - General Information - 5.0L 32V Ti-VCT/5.

Fuel System - Overview

The fuel system consists of the :

saddle-type fuel tank.

Fuel Pump Shut-off Feature

Copyright © 2016 Ford Motor Company

Symptom Chart: Fuel System

Normal Operation and Fault Conditions

PINPOINT TEST A : SLOW TO FILL

Was the cause of the concern found?

Yes REPAIR or INSTALL new components to correct the concern.

A2 CHECK THE SYSTEM FOR ANY EVAP (EVAPORATIVE EMISSION) DTC'S

Are any DTC's present?

Yes Refer to Powertrain Control/Emissions Diagnosis (PC/ED) manual.

A3 MONITOR THE FTP WHILE FILLING THE FUEL TANK

Is FTP within specification?

A6 CHECK THE FUEL TANK INLET CHECK VALVE

Is the fuel tank inlet check valve restricted or sticking?

Copyright © 2016 Ford Motor Company

Fuel System Pressure Check

Special Tool(s) / General Equipment

1. Release the fuel system pressure.

3. Disconnect the fuel jumper tube-to-fuel rail quick release coupling.

Reconnect the FPDM electrical connector.

Copyright © 2016 Ford Motor Company

Fuel Tank Draining

Special Tool(s) / General Equipment

1. Release the fuel system pressure.

2. Disconnect the battery ground cable.

3. NOTE: The supplemental refueling adapter is located in the luggage compartment.

5. Remove the rear seat cushion.

6. Remove the access cover and position aside.

Remove and discard the O-ring seal.

11. Remove the access cover and position aside.

Disconnect the electrical connector.

Remove and discard the Fuel Level Sensor O-ring seal.

Copyright © 2016 Ford Motor Company

Quick Release Coupling

2. Disconnect the battery ground cable.

1. Inspect and clean both quick coupling ends.

2. Disconnect the battery ground cable.

3. Connect the battery ground cable.

2. Disconnect the battery ground cable.

3. Connect the battery ground cable.

2. Disconnect the battery ground cable.

2. Disconnect the battery ground cable.

2. Disconnect the battery ground cable.

3. 1. Release the secondary locking tab.

1. 1. Push the quick release coupling onto the tube.

2. Connect the battery ground cable.

Copyright © 2016 Ford Motor Company

Spring Lock Couplings

Special Tool(s) / General Equipment

2. Disconnect the battery ground cable.

3. If equipped, remove the fuel tube safety clip.