Special Tool(s)

WARNING: This page is about a different car, the 2010 Mercury Mariner and 2010 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.

SPECIAL TOOL DESCRIPTION CHART

Courtesy of FORD MOTOR CO.	Fuel Storage Tanker 164-R3202 or equivalent
Courtesy of FORD MOTOR CO.	Wrench, Fuel Tank Sender Unit 310-123

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: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions 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.

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.

Release the fuel system pressure. For additional information, refer to FUEL SYSTEM PRESSURE RELEASE .
Disconnect the battery ground cable. For additional information, refer to BATTERY DISCONNECT .
Remove the Fuel Pump (FP) module access cover.

Fig 1: Locating Fuel Pump (FP) Module Access Cover
Courtesy of FORD MOTOR CO.

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

Fig 2: Locating FP Module Electrical Connector

Courtesy of FORD MOTOR CO.

Disconnect the FP module electrical connector.

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

Fig 3: Locating Fuel Tube-To-FP Module Quick Connect Coupling

Courtesy of FORD MOTOR CO.

Disconnect the fuel tube-to- FP module quick connect coupling. For additional information, refer to QUICK CONNECT COUPLING .
Disconnect the fuel tank filler pipe recirculation tube-to- FP module quick connect coupling. For additional information, refer to QUICK CONNECT COUPLING .

Fig 4: Locating Fuel Tank Filler Pipe Recirculation Tube-To-FP Module Quick Connect Coupling
Courtesy of FORD MOTOR CO.

NOTE: For initial fuel draining, it is required to remove the fuel through the fuel tank filler pipe recirculation tube port on the FP module.

Fig 5: Locating Fuel Through Fuel Tank Filler Pipe Recirculation Tube Port On FP Module

Courtesy of FORD MOTOR CO.

Connect the Fuel Storage Tanker to the fuel tank filler pipe recirculation tube port on the FP module and remove approximately one-fourth of the fuel (from a completely full tank), lowering the fuel level below the FP module mounting flange.

NOTE: Carefully install the Fuel Tank Sender Unit Wrench to avoid damaging the FP module when removing the lock ring.

NOTE: When installing the FP module, install a new O-ring seal.

Fig 6: Identifying Fuel Tank Sender Unit Wrench

Courtesy of FORD MOTOR CO.

Install the Fuel Tank Sender Unit Wrench and remove the FP module lock ring.

NOTE: The Fuel Pump (FP) module must be handled carefully to avoid damage to the float arm and filter.

Fig 7: Locating Fuel Storage Tanker Tube

Courtesy of FORD MOTOR CO.

Position the FP module aside, insert the tube from the Fuel Storage Tanker into the FP module aperture and remove as much fuel as possible from the fuel tank.