Fuel Pump Module - Plastic Fuel Tank (Gasoline): Removal

WARNING: This page is about a different car, the 2010 Ford Pickup, 2010 Ford F550 Super Duty, 2010 Ford F450 Super Duty, and 2010 Ford Cab & Chassis. 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: 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.

NOTE: This procedure is for gasoline applications with plastic fuel tank only.

NOTE: The fuel tank must be drained completely. Upon removal of the Fuel Pump (FP) module, the tank must be inspected for contamination.

Remove the fuel tank. For additional information, refer to FUEL TANK - MIDSHIP .

NOTE: Clean the fuel tank of any dirt or foreign material before servicing the Fuel Pump (FP) module. In extreme dirt or dusty conditions it may be necessary to wash the fuel tank using a water hose. Before removing the FP module, make sure that there is no residual dirt or foreign material around the FP module flange. If dirt or foreign material enter the fuel tank, damage to the FP module or other fuel system components may occur.

Clean the area around the FP module mounting flange.

NOTE: Mark the orientation of the FP module on the fuel tank to aid in installation.

Fig 1: Removing FP Module Lock Ring Using Lock Ring Wrench

Courtesy of FORD MOTOR CO.

Using the Lock Ring Wrench, remove the FP module lock ring.

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

Completely remove the FP module from the fuel tank.

NOTE: Inspect the surfaces of the FP module flange and 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 or fuel leakage could occur.

NOTE: Make sure to install a new FP module O-ring seal and lock ring or fuel leakage could occur.

NOTE: Apply clean engine oil to the O-ring seal prior to installation.

Remove and discard the FP module O-ring seal.