Fuel Tank and FPCM
Posted: 23 Mar 2024, 22:25
To allow the propshaft to run down the center tunnel the fuel tank is a saddle type (see pic below). Both the Volvo S40/V50 and Kuga TE tanks are the same so you can use either. You'll need the support straps as they are different to the FWD tank and you'll need to add a nut insert into the chassis hole on the passenger side for the rear strap mount.
Being a saddle the tank has two sender units but only one fuel pump. The two sender units feed directly to the instrument cluster (IC) where the software reconciles the two readings to give a singly value on the gauge. Note this doesn't work when you use an XR5 IC as its missing the software to do the calculation. The fuel pump is interesting as there has to be a way to get fuel from the LHS saddle across to the right, and it's done by a venturi effect (Ford call it a Jet Pump). Basically the pump has another suction hole at the base that feeds from the LHS saddle by creating a vacuum across the hole consequently sucking fuel across. What this means is that you cannot replace the in-tank pump with a higher flow pump like you do in the XR5/RS when doing power upgrades. Fortunately though, the AWD pump has extra capability and from all accounts is good to about 500hp. The Fuel Tank section 310 in the Kuga Workshop Manual gives a good overview of the fuel system (see in AWD General Info - Technical Documents).
The other difference with the fuel pump is that it's controlled by a Fuel Pump Control Module (FPCM) which sits under the driver's side rear seat. Here is a pic of the part number.
And here it is located in its natural environment under the RHS rear seat in a TE Kuga.
This module controls the speed of the pump and itself takes a PWM (Pulse Width Modulated) feed from Pin 21 on the PCM. If you don't wire this in you'll get a high fuel rail pressure DTC as soon as you start the car. Luckily the XR5 PCM is active on pin 21 even though it's not used, so it's almost a plug & play solution.
Being a saddle the tank has two sender units but only one fuel pump. The two sender units feed directly to the instrument cluster (IC) where the software reconciles the two readings to give a singly value on the gauge. Note this doesn't work when you use an XR5 IC as its missing the software to do the calculation. The fuel pump is interesting as there has to be a way to get fuel from the LHS saddle across to the right, and it's done by a venturi effect (Ford call it a Jet Pump). Basically the pump has another suction hole at the base that feeds from the LHS saddle by creating a vacuum across the hole consequently sucking fuel across. What this means is that you cannot replace the in-tank pump with a higher flow pump like you do in the XR5/RS when doing power upgrades. Fortunately though, the AWD pump has extra capability and from all accounts is good to about 500hp. The Fuel Tank section 310 in the Kuga Workshop Manual gives a good overview of the fuel system (see in AWD General Info - Technical Documents).
The other difference with the fuel pump is that it's controlled by a Fuel Pump Control Module (FPCM) which sits under the driver's side rear seat. Here is a pic of the part number.
And here it is located in its natural environment under the RHS rear seat in a TE Kuga.
This module controls the speed of the pump and itself takes a PWM (Pulse Width Modulated) feed from Pin 21 on the PCM. If you don't wire this in you'll get a high fuel rail pressure DTC as soon as you start the car. Luckily the XR5 PCM is active on pin 21 even though it's not used, so it's almost a plug & play solution.