Removal and Installation

WARNING: This page is about a different car, the 2010 Mercury Milan, 2010 Lincoln MKZ, and 2010 Ford Fusion. 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: 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.

NOTE: Vehicles with an inaccurate or inoperable fuel gauge, follow the instructions for draining a fuel tank with more than one-half of a tank of fuel.

All vehicles

Release the fuel system pressure. For additional information, refer to FUEL SYSTEM PRESSURE RELEASE .
Disconnect the battery ground cable. For additional information, refer to REMOVAL AND INSTALLATION (2.5L), REMOVAL AND INSTALLATION (3.0L) and REMOVAL AND INSTALLATION (3.5L) .
Remove the rear seat lower cushion. For additional information, refer to REMOVAL AND INSTALLATION .
2.5L and 3.5L vehicles with more than one-half of a tank of fuel
Install the supplemental refueling adapter and a length of semi-rigid fuel drain tube into the Easy Fuel™ (capless) fuel tank filler pipe until the tube enters the fuel tank.
NOTE: The supplemental refueling adapter is located in the luggage compartment.

Fig 1: Identifying Supplemental Refueling Adapter & Semi-Rigid Fuel Drain Tube
Courtesy of FORD MOTOR CO.
Attach the Fuel Storage Tanker to the fuel drain tube and remove one-half (approximately 8 gallons) of fuel from the tank.
NOTE: This step is to remove approximately one-half tank of the fuel from a completely full fuel tank and the majority of any residual fuel in the fuel tank filler pipe, lowering the fuel level below the Fuel Pump (FP) module mounting flange.

3.0L vehicles with more than one-half of a tank of fuel

NOTE: The Easy Fuel™ (capless) fuel tank filler pipe on 3.0L vehicles have an anti-siphon grate that will not allow a fuel drain tube to penetrate the fuel tank and requires the following steps to drain the fuel.
With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
Install the supplemental refueling adapter and a length of semi-rigid fuel drain tube into the Easy Fuel™ (capless) fuel tank filler pipe.
NOTE: The supplemental refueling adapter is located in the luggage compartment.

Fig 2: Identifying Supplemental Refueling Adapter & Semi-Rigid Fuel Drain Tube
Courtesy of FORD MOTOR CO.
Attach the Fuel Storage Tanker to the fuel drain tube and remove any residual fuel in the fuel tank filler pipe.
Release the clamp and disconnect the hose from the fuel tank filler pipe.
- To install, tighten to 4 Nm (35 lb-in).
NOTE: Index-mark the fuel tank filler pipe hose and the clamp prior to removal for correct installation.

Fig 3: Locating Fuel Tank Filler Pipe Hose Clamp
Courtesy of FORD MOTOR CO.
Insert a semi-rigid fuel drain tube into the fuel tank filler pipe hose until it enters the fuel tank.

Fig 4: Inserting Semi-Rigid Fuel Drain Tube Into Fuel Tank Filler Pipe Hose
Courtesy of FORD MOTOR CO.
Attach the Fuel Storage Tanker to the fuel drain tube and remove one-half (approximately 8 gallons) of fuel from the tank.
NOTE: This step is to remove approximately one-half tank of the fuel from a completely full fuel tank, lowering the fuel level below the FP module mounting flange.

All vehicles
Remove the 3 screws and the FP module access cover.
- To install, tighten to 2 Nm (18 lb-in).
Disconnect the FP module electrical connector.
NOTE: Clean the FP module connections, couplings, flange surfaces and the immediate surrounding area of any dirt or foreign material.
Disconnect the fuel tube-to-FP module quick connect coupling. For additional information, refer to QUICK CONNECT COUPLING .
Install the Fuel Tank Sender Unit Wrench and remove the FP module lock ring.
NOTE: Place absorbent pads on the floor pan in the immediate area in case of fuel spills. Carefully remove the FP module from the vehicle to avoid fuel spillage inside the vehicle.

NOTE: Make sure to install a new FP module O-ring seal.

Fig 5: Identifying Fuel Tank Sender Unit Wrench
Courtesy of FORD MOTOR CO.
Carefully lift the FP module out of the fuel tank enough to access and release the internal fuel tube-to- FP module quick connect coupling. For additional information, refer to QUICK CONNECT COUPLING .
Carefully remove the FP module from the fuel tank.
NOTE: The Fuel Pump (FP) module must be handled carefully to avoid damage to the float arm.

NOTE: The FP module will have residual fuel remaining internally, drain into a suitable container.
Remove and discard the FP module O-ring seal.
NOTE: Inspect the mating surfaces of the Fuel Pump (FP) 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 FP module or fuel tank if the O-ring seal contact area is bent, scratched or corroded.

NOTE: To install, apply clean engine oil to the new O-ring seal.
To install, reverse the removal procedure.
- Make sure the alignment tab on the FP module and the fuel tank meet before tightening the FP module lock ring.