Ford Fusion Quiz
Powertrain

Fuel System. Diagnosis and Testing

In this manual: Powertrain
General Information — 26Chassis — 150Powertrain — 282Electrical — 271Body and Paint — 300
~2min read

Symptom Chart

Symptom Chart: Fuel System

The diagnosis in this manual assumes a certain level of skill and knowledge of Ford-approved diagnostic methods.
Refer to: Diagnostic Methods (100-00 General Information, Description and Operation).
for information on Ford diagnostic methods.


Symptom Chart


Condition Possible Sources Action
Slow Refueling
  • Fuel tank filler pipe
  • Fuel tank filler tube vent hose, if equipped
  • Evaporative Emission Control System (EVAP)
  • Fuel tank inlet check valve (part of the fuel tank)
  • Fuel level vent valve (part of the fuel tank)
 Refer to Diagnostic Procedure A: Slow Fill. GO to Pinpoint Test A.
All Other Fuel System Concerns Fuel System Components Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.

Diagnostic Procedure(s)

Slow Refueling

Normal Operation and Fault Symptoms

During normal operation, fuel should flow at a steady rate through the fuel fill pipe into the fuel tank. As fuel enters the fuel tank, air is vented through the fill pipe or the ORVR system.


DIAGNOSTIC TEST A: SLOW FILL
A1 CHECK THE COMPONENTS FOR DAMAGE
  • Visually inspect the following components for signs of damage:
    • Fuel tank filler pipe
    • Fuel tank filler tube vent hose, if equipped
    • EVAP system
    • Fuel tank inlet check valve (part of the fuel tank)
    • Fuel level vent valve (part of the fuel tank)

Was a concern found?
Yes REPAIR or INSTALL new components to correct the condition.
No GO to A2
A2 CHECK THE FUEL TANK FILL PIPE ASSEMBLY FOR A BLOCKAGE OR RESTRICTION
  • Remove the fuel filler pipe assembly.
    REFER TO: Fuel Tank Filler Pipe (310-01A Fuel Tank and Lines - 1.5 L EcoBoost (118 kW/160 L PS) - I4, Removal and Installation).
  • Inspect the fuel tank filler pipe and the fuel tank filler pipe vent tube (if equipped) for a blockage or restriction.

Is the fuel tank fill pipe or fuel tank fill pipe vent tube (if equipped) blocked or restricted?
Yes If possible, CLEAR the blockage or restriction. If the blockage or restriction cannot be cleared, INSTALL a new fuel tank fill pipe or fuel tank fill pipe vent tube.
No GO to A3
A3 CHECK THE FUEL TANK INLET CHECK VALVE
  • Inspect the fuel tank inlet check valve for sticking or binding.

Is the fuel tank inlet check valve stuck or sticking?
Yes If possible, CLEAR the restriction. If the restriction cannot be cleared, INSTALL a new fuel tank.
REFER TO: Fuel Tank (310-01A Fuel Tank and Lines - 1.5 L EcoBoost (118 kW/160 L PS) - I4, Removal and Installation).
No INSTALL a new fuel tank.

Test yourself

A quick Ford Fusion quiz: every answer comes with an explanation and a link to the manual page.