Special Tool(s)

WARNING: This page is about a different car, the 2011 Mercury Milan, 2011 Lincoln MKZ, and 2011 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

SPECIAL TOOL(S)

	Fuel Storage Tanker 164-R3202 or equivalent
	Fuel Tank Sender Unit Wrench 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.

NOTE: For (Front Wheel Drive (FWD)) vehicles with an inaccurate or inoperable fuel gauge, follow the instructions for draining a fuel tank with more than three-fourths of a tank of fuel.

NOTE: For (All-Wheel Drive (AWD)) 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 in this service information.
Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING & CABLES -- FUSION, MILAN & MKZ article.
Remove the rear seat lower cushion. For additional information, refer to SEAT SYSTEM - SEATS -- FUSION, MILAN & MKZ article.
Front Wheel Drive (FWD) vehicles with more than three-fourths tank of fuel

NOTE: The supplemental refueling adapter is located in the luggage compartment.

Fig 1: Locating Supplemental Refueling Adapter And Semi-Rigid Fuel Drain Tube (FWD)

Courtesy of FORD MOTOR CO.

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: This step will remove approximately one-fourth 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.

Attach the Fuel Storage Tanker to the fuel drain tube and remove one-fourth (approximately 4 gallons) of fuel from the tank.
All-Wheel Drive (AWD) vehicles with more than one-half tank of fuel

NOTE: The supplemental refueling adapter is located in the luggage compartment.

Fig 2: Locating Supplemental Refueling Adapter And Semi-Rigid Fuel Drain Tube (AWD)

Courtesy of FORD MOTOR CO.

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: 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.
Attach the Fuel Storage Tanker to the fuel drain tube and remove one-half (approximately 9 gallons) of fuel from the tank.

FWD vehicles
Remove the 4 screws and the FP module access cover.

Fig 3: Locating FP Module Access Cover Screws (FWD)
Courtesy of FORD MOTOR CO.

AWD vehicles
Remove the 3 screws and the FP module access cover.

Fig 4: Locating FP Module Access Cover Screws (AWD)
Courtesy of FORD MOTOR CO.

All vehicles

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

Fig 5: 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 6: 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 .

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

Fig 7: Removing FP Module Lock Ring

Courtesy of FORD MOTOR CO.

Install the Fuel Tank Sender Unit Wrench, remove the FP module lock ring.
- Discard the FP module O-ring seal.

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

Fig 8: Inserting Tube From Fuel Storage Tanker Into FP Module Aperture & Drain

Courtesy of FORD MOTOR CO.

Position the FP module aside and insert the tube from the fuel storage tanker into the FP module aperture and drain as much fuel from the fuel tank as possible.
AWD vehicles
Remove the 3 screws and the fuel level sensor access cover.

Fig 9: Locating Fuel Level Sensor Access Cover Screws (AWD Vehicles)
Courtesy of FORD MOTOR CO.

NOTE: Clean the fuel level sensor electrical connector, flange surface and the immediate surrounding area of any dirt or foreign material.

Fig 10: Locating Fuel Level Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

Disconnect the fuel level sensor electrical connector.

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

Fig 11: Rotating Fuel Level Sensor Counterclockwise

Courtesy of FORD MOTOR CO.

Release the lock tab and rotate the fuel level sensor counterclockwise approximately one-fourth turn, lift and position aside.
Insert the tube from the Fuel Storage Tanker into the fuel level sensor aperture and drain the remainder of the fuel from the fuel tank.

Fig 12: Locating Fuel Storage Tanker Tube

Courtesy of FORD MOTOR CO.