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Fuel System Pressure Test

SPECIAL TOOLS

G06064437
 Adapter, Fuel Pressure Test
310-180
G06064438
 Fuel Pressure Test Kit
310-D009 (D95L-7211A)
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.
WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.
NOTE: Early build 3.0L engines are equipped with a Schrader valve on the fuel rail. Late build 3.0L engines do not have a Schrader valve.

2.5L engine 

  1. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM PRESSURE RELEASE  .
  2. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  3. Disconnect the fuel jumper tube-to-fuel rail quick connect coupling. For additional information, refer to QUICK CONNECT COUPLING  .
  4. Install the Fuel Pressure Test Kit between the fuel jumper tube and the fuel rail.
    Fig 1: Identifying Fuel Pressure Test Kit Between Fuel Tube And Fuel Rail (2.5L Engine)
    G06098451Courtesy of FORD MOTOR CO.
    5. NOTE: The Fuel Pump (FP) control module was disconnected in the fuel system pressure release.
  5. Connect the FP control module electrical connector.
  6. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .

    Early build 3.0L engine 

  7. Remove the fuel rail Schrader valve cap.
    Fig 2: Location of Fuel Rail Schrader Valve Cap
    G06098452Courtesy of FORD MOTOR CO.
  8. Install the Fuel Pressure Test Kit to the fuel rail Schrader valve.
    Fig 3: Location of Side Air Bag Module Studs And Locator Pin
    G06098453Courtesy of FORD MOTOR CO.

    Late build 3.0L engine 

  9. Disconnect the fuel jumper tube-to-fuel tube quick connect coupling. For additional information, refer to QUICK CONNECT COUPLING  .
  10. Install the Fuel Pressure Test Kit between the fuel jumper tube and the fuel tube.
    Fig 4: Identifying Fuel Pressure Test Kit Between Fuel Jumper Tube And Fuel Tube (Late Build 3.0L Engine)
    G07786952Courtesy of FORD MOTOR CO.

    3.5L engine 

  11. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM PRESSURE RELEASE  .
  12. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  13. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 3.5L .
  14. Disconnect the fuel tube-to-fuel rail spring lock coupling. For additional information, refer to SPRING LOCK COUPLINGS  .
  15. Install the Fuel Pressure Test Adapter and Fuel Pressure Test Kit between the fuel tube and the fuel rail.
    Fig 5: Identifying Fuel Pressure Test Adapter And Fuel Pressure Test Kit Between Fuel Tube And Fuel Rail (3.5L Engine)
    G07786953Courtesy of FORD MOTOR CO.
    16. NOTE: The ACL outlet pipe must be installed prior to completing the fuel system pressure test.
  16. Install the ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 3.5L .
    17. NOTE: The Inertia Fuel Shutoff (IFS) switch was disconnected in the fuel system pressure release.
  17. Connect the IFS switch electrical connector.
  18. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .

    All engines 

    19. NOTE: Carry out a Key ON Engine OFF (KOEO) visual inspection for fuel leaks prior to completing the fuel system pressure test.
    NOTE: After completion of the fuel system pressure test, open the drain valve on the Fuel Pressure Test Kit and release any residual fuel into a suitable container prior to removing the tool.
  19. Test the fuel system pressure to make sure it is within the specified range. For additional information, refer to SPECIFICATIONS  .
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