Removal and Installation

WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in 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 components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.

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.

Release the fuel system pressure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Release the fuel tank filler cap and position it aside.

CAUTION: Upon removing the special tool, the fitting on the end of the hose can become detained by the one way flapper valve. Carefully remove the hose using a gentle agitating motion to avoid detaching the hose from the fitting.

NOTE: The special tool must be inserted into the fuel tank filler pipe until the fitting on the end of the hose enters into the fuel tank spout, opening the one way flapper valve.

Fig 1: Identifying Special Tool

Courtesy of FORD MOTOR CO.

Insert the special tool into the fuel tank filler pipe.

NOTE: This step will remove approximately 1/8 tank of the fuel from a completely full fuel tank and the majority of any residual fuel in the fuel tank filler pipe.

Attach the fuel storage tanker to the special tool and remove as much fuel as possible from the fuel tank and fuel tank filler pipe.
Remove the rear seat lower cushion. For additional information, refer to SEATING .
Position the carpet and/or any insulation covering the fuel pump module access cover.
Remove the 4 screws and the fuel pump module access cover.

Fig 2: Locating Fuel Pump Module Access Cover Screws
Courtesy of FORD MOTOR CO.
Disconnect the fuel pump module electrical connector.
Disconnect the fuel supply tube-to-fuel pump module quick connect coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
Using the special tool, remove the fuel pump module lock ring retainer.

Fig 3: Removing Fuel Pump Module Lock Ring Retainer
Courtesy of FORD MOTOR CO.

CAUTION: The fuel pump module must be handled carefully to avoid damage to the float arm.

CAUTION: Place absorbent pads on the floor pan in the immediate area in case of fuel spills. Carefully remove the fuel pump module from the vehicle to avoid fuel spillage inside the vehicle.

CAUTION: The fuel pump module will have residual fuel remaining internally, drain into a suitable container

Completely remove the fuel pump module from the fuel tank.

CAUTION: Inspect the mating surfaces of the fuel pump module flange and the 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 module or fuel tank if the O-ring seal contact area is bent, scratched or corroded.

CAUTION: Make sure to install a new fuel pump module O-ring seal. Install a new lock ring if it is bent, damaged or corroded.

NOTE: To install, apply clean engine oil to the O-ring seal.

Remove the fuel pump module O-ring seal.
To install, reverse the removal procedure.
- Make sure the alignment tab on the fuel pump module and the fuel tank meet before tightening the fuel pump module lock ring.