Attachment III - Technical Information

FUEL DELIVERY MODULE (FDM) REPLACEMENT

AFFECTED VEHICLES:
ALL 2000 MODEL YEAR TAURUS/SABLE EQUIPPED WITH 3.0L FFV

OVERVIEW
Replacement of the Fuel Delivery Module (FDM) will require draining and removal of the fuel tank. A new FDM mounting gasket will be installed along with new locking clips for the fuel line connections.

FUEL DRAINING

WARNING:
DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY.

1. Install a memory saver, then disconnect the battery negative cable.

WARNING:
FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD.

2. Release the fuel system pressure as follows:

^ Remove the cap from the Schrader valve located on the engine fuel rail.

^ Attach an EFI/CFI fuel pressure gauge to the Schrader valve.

^ Slowly open the manual valve on the fuel pressure gauge to relieve the fuel system pressure.

^ Remove the fuel pressure gauge, then install the cap on the Schrader valve.

3. Raise and support the vehicle.





4. Disconnect the large fuel tank filler pipe hose. See Figure 1.

5. Connect Fuel Draining Tool 310-K013 to a fuel storage tanker hose.

6. Position the Fuel Draining Tool 310-K013 into the large fuel tank filler pipe hose. See Figure 1.

7. Siphon fuel from the tank until it is empty, then remove Fuel Draining Tool 310-K013.

8. Disconnect the remaining fuel tank filler pipe hose and the vapor tube fitting. See Figure 1.

FDM - REMOVAL





1. Disconnect the FDM electrical connector. See Figure 2.

2. Disconnect the fuel filter inlet line and discard the locking clip. See Figure 2.

3. Support the fuel tank with a suitable jack.

4. Remove the bolts and lower the fuel tank support straps away from the fuel tank.

5. Lower the fuel tank from the vehicle.

6. Clean the area around the FDM mounting flange.





7. Disconnect the FDM to fuel filter hose and discard the locking clip. See Figure 3.

8. Disconnect the fuel tank pressure transducer electrical connector. See Figure 3.

9. Unclip the FDM electrical connector from the fuel tank. See Figure 3.





10. Remove the FDM lockring with Fuel Tank Lockring Wrench 310-D006. See Figure 4.

CAUTION:
The FDM will contain some residual fuel.

11. Remove the FDM and the FDM mounting gasket from the fuel tank and discard.

FDM - INSTALLATION

1. Install the new FDM mounting gasket included in the kit

NOTE:
There are two (2) locating tabs on the rim of the FDM which engage in matching notches in the opening of the fuel tank. Also, the locating dimple on the fuel tank may be covered by a foam spacer block adhered to the top of the tank.





2. Install the FDM as follows. See Figure 5.

^ Position the new FDM into the opening of the fuel tank, aligning the arrow on the FDM with the dimple on the fuel tank.

^ Press the FDM into the opening of the fuel tank to engage the locating tabs, then rotate the FDM slightly clockwise to lock the FDM into position.

^ Install the FDM lockring with Fuel Tank Lockring Wrench 310-D006.

3. Clip the FDM electrical connector onto the fuel tank.

4. Connect the fuel tank pressure transducer electrical connector.

5. Connect the FDM to fuel filter hose. Install the new locking clip included in the kit.

6. Support the fuel tank with a suitable jack.

7. Raise and install the fuel tank in the vehicle.

8. Install the fuel tank support straps. Tighten the bolts to 35 Nm (26 lb-ft).

9. Connect the fuel filter inlet line. Install the new locking clip included in the kit.

10. Connect the FDM electrical connector.

11. Connect the fuel tank filler pipe hoses and vapor tube fitting.

12. Lower the vehicle.

13. Refill the fuel tank.

14. Connect the battery negative cable, then remove the memory saver.

15. Turn the ignition key to the "ON" position to pressurize the fuel system, and check for leaks.