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Removal and Installation

WARNING: This page is about a different car, the 2004 Lincoln LS. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible 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.
  1. If the fuel tank, fuel transfer pump or fuel delivery module is being removed drain the fuel tank. For additional information, refer to FUEL TANK DRAINING .
  2. If the fuel tank is being removed, remove the driveshaft. For additional information, refer to DRIVELINE SYSTEM .
  3. Remove the parts in the order indicated in the following illustrations and tables.

    To remove individual parts, only carry out the listed steps:  See INDIVIDUAL PARTS REMOVAL STEPS .

    INDIVIDUAL PARTS REMOVAL STEPS

    Part Steps
    Fuel filler pipe 1-5
    Fuel tank 6, 8-17
    Fuel transfer pump 18-24
    Fuel delivery module 18-27
    Fig 1: Exploded View Of Fuel Filler Pipe
    G03202112Courtesy of FORD MOTOR CO.
    Fig 2: Exploded View Of Fuel transfer pump
    G03202113Courtesy of FORD MOTOR CO.
  4. To install, reverse the removal procedure.
  5. Fill the fuel tank.
  6. Turn the ignition key to the ON position to pressurize the fuel system.
  7. Visually inspect the fuel system for leaks.

Item 5: Fuel Filler Pipe Removal Note 

  1. Remove the right rear well inner fender splash shield.
    2. CAUTION: Some fuel will remain in the filler pipe after draining the fuel tank. Carefully drain the filler pipe into an approved container.
    Fig 3: Loosening Clamp
    G03202114Courtesy of FORD MOTOR CO.
  2. Loosen the clamp at the fuel tank filler pipe and remove the filler pipe.

Item 8: Fuel Tube Shield Removal Note 

  1. Position the fuel tube shield aside.
    1. Remove the pin-type retainers.
    2. Remove the bolt.
    Fig 4: Removing Bolt
    G03202115Courtesy of FORD MOTOR CO.

Item 12: Fuel Tank Strap Mounting Bolt Removal Note 

  1. Remove the bolts and the heat shield.
    Fig 5: Removing Bolts And Heat Shield
    G03202116Courtesy of FORD MOTOR CO.
  2. Position a suitable lifting device to support the fuel tank.
    Fig 6: Positioning Suitable Lifting Device Support Fuel Tank
    G03202117Courtesy of FORD MOTOR CO.

Item 16: Vapor Tube Quick Connect Fitting Removal Note 

  1. Partially lower the fuel tank and disconnect the vapor tube.
    Fig 7: Identifying Vapor Tube
    G03202118Courtesy of FORD MOTOR CO.

Item 23: Fuel Crossover Hose Quick Connect Fitting Removal Note 

    NOTE: The routing of the internal fuel crossover hoses is critical to correct fuel system operation. Note the routing of the internal fuel crossover hoses at this time.
    Fig 8: Locating Fuel Transfer Pump
    G03202119Courtesy of FORD MOTOR CO.
  1. Partially raise the fuel transfer pump and disconnect the internal fuel crossover hose quick connect fittings.

Item 26: Fuel Delivery Module Removal Note 

    CAUTION: Drain the remaining fuel from the delivery module into the fuel tank prior to removal.
    Fig 9: Removing Fuel Delivery Module And Crossover Lines
    G03202120Courtesy of FORD MOTOR CO.
  1. Before removal, attach a non-conductive material to the crossover line. Then remove the fuel delivery module and crossover lines as an assembly, using the non-conductive material to pull the crossover lines through the gas tank.

Item 26: Fuel Delivery Module Installation Note 

    NOTE: Install the fuel delivery module and crossover lines as an assembly.
  1. Attaching the non-conductive material to the crossover lines, pull the crossover lines through the gas tank to install the fuel delivery module.

Item 25: Fuel Delivery Module Lock Ring Installation Note 

  1. Using the special tool, install the fuel delivery module lock ring.
    Fig 10: Installing Fuel Delivery Module Lock Ring Using Special Tool
    G03202121Courtesy of FORD MOTOR CO.

Item 23: Fuel Crossover Hose Quick Connect Fittings Installation Note 

    NOTE: Make sure that the fuel crossover hoses are routed correctly.
    Fig 11: Identifying Fuel Transfer Pump And Connecting Fuel Crossover Hose
    G03202122Courtesy of FORD MOTOR CO.
  1. Raise the fuel transfer pump and connect the fuel crossover hose quick connect fittings.

Item 22: Fuel Transfer Pump Installation Note 

  1. Partially install the fuel transfer pump.

Item 21: Fuel Transfer Pump Lock Ring Installation Note 

  1. Using the special tool, install the fuel transfer pump lock ring.
    Fig 12: Installing Fuel Transfer Pump Lock Ring Using Special Tool
    G03202123Courtesy of FORD MOTOR CO.

Item 8: Fuel Tube Shield Installation Note 

  1. Install the fuel tube shield.
    1. Install the pin type retainers.
    2. Install the bolt.
    Fig 13: Identifying Pin Type Retainers
    G03202124Courtesy of FORD MOTOR CO.
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