Removal And Installation

WARNING: This page is about a different car, the 2008 Mercury Mariner and 2008 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.

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: Remove the fuel filler cap slowly. The fuel system may be under pressure. If the fuel filler cap is venting vapor or if you hear a hissing sound, wait until it stops before completely removing the fuel filler cap. Otherwise, fuel may spray out. Failure to follow these instructions may result in serious personal injury.

Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
Release the fuel tank filler cap and position aside.
Insert the special tool into the fuel tank filler pipe until it opens the fuel level shutoff valve located at the inlet of the fuel tank.

Fig 1: Identifying Special Tool 310-102

Courtesy of FORD MOTOR CO.

NOTE: Due to the internal design of the fuel tank components, slow fuel drainage may occur.

Using the special tools, drain as much fuel as possible from the fuel tank and filler pipe, lowering the fuel level below the fuel pump (FP) mounting flange.
Remove the 4 screws and the FP module access cover.

NOTE: Clean the FP module connection, couplings, mounting flange and the immediate surrounding area of any dirt or foreign material.

Disconnect the FP module electrical connector.

NOTE: Place absorbent toweling in the immediate surrounding area in case of fuel spills.

Disconnect the fuel supply tube and fuel vapor recirculation tube-to-FP module quick connect couplings. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.

CAUTION: The fuel pump (FP) module must be handled carefully to avoid damage to the float arm and the filter.

NOTE: Carefully remove the FP module lock ring and verify that enough fuel has been drained to avoid spillage.

NOTE: Drain any residual fuel in the FP module into a suitable container.

Using a suitable FP module lock ring remover, rotate the lock ring counterclockwise and remove the FP module.

NOTE: Inspect the surfaces of the FP module flange and fuel tank seal contact surfaces. Do not polish or adjust the seal contact area of the FP module flange or fuel tank. Install a new FP module or fuel tank if the seal contact area is bent, scratched or corroded.

Remove and discard the FP module O-ring seal.

NOTE: Apply clean engine oil to the FP module O-ring seal.

To install, reverse the removal procedure.