Fuel Tank: Installation

All vehicles 

CAUTION: Inspect the surfaces of the fuel pump module flange and fuel tank O-ring contact surfaces. Do not polish or adjust the O-ring contact area of the fuel pump flange or fuel tank. Install a new fuel pump module or fuel tank if the O-ring contact area is bent, scratched or corroded.
CAUTION: Make sure to install a new fuel pump module O-ring and lock ring.
NOTE: Lubricate the fuel pump module O-ring seal with clean engine oil.
1. Install a new fuel pump module O-ring seal and fuel pump module lock ring.
NOTE: When installing the fuel pump module, make sure to align the locator tabs on the fuel tank mounting flange.
2. Install the fuel pump module.
Fig 1: Aligning Fuel Pump Module
Courtesy of FORD MOTOR CO.
NOTE: Be sure the aligning tabs of the fuel pump module unit are positioned in the slot before tightening the lock ring.
3. Holding the fuel pump module O-ring seal in place, rotate the lock ring clockwise until it stops against the retainer tabs.
4. Position the fuel tank on a suitable lift and raise the tank enough to connect the fuel vapor control tube valve assembly quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
   • Raise the tank into the installed position.
5. Install the RH fuel tank strap and bolt.
   • Tighten to 55 Nm (41 lb-ft).
6. Install the LH fuel tank strap and bolt.
   • Tighten to 55 Nm (41 lb-ft).
7. Attach the wiring harness pin-type retainers to the fuel tank strap.
8. Install the fuel filler pipe hose and clamp to the fuel tank.
   • Tighten to 4 Nm (36 lb-in).
9. Connect the fuel supply tube quick connect coupling For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
10. Connect the fuel pump module electrical connector.
11. Connect the fuel tank pressure sensor electrical connector.
12. Install the fuel pump module access cover and screws.
13. Reposition the carpet and install the LH rear seat cushion.

All wheel drive (AWD) vehicles 

14. Install the rear driveshaft. For additional information, refer to DRIVESHAFT article.
15. Position the exhaust system and install the rear hangers.

All vehicles 

16. Install the fuel tank filler cap.
17. Turn the ignition key to the ON position to pressurize the fuel system.
18. Visually inspect the fuel system for leaks.