Special Tool(s)

SPECIAL TOOLS 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, MOUNTING AND CABLES .
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 Quick Connect Coupling

Courtesy of FORD MOTOR CO.

Disconnect the fuel tank jumper tube-to- FP module quick connect coupling. For additional information, refer to QUICK CONNECT COUPLING .
Connect the Fuel Storage Tanker to the FP module outlet fitting and remove approximately one-fourth of the fuel (from a completely full tank), lowering the fuel level below the FP module mounting flange.

Fig 4: Locating FP Module Mounting Flange
Courtesy of FORD MOTOR CO.

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 lock ring and O-ring seal.

Fig 5: Removing FP Module Lock Ring

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 6: Locating Tube From Fuel Storage Tanker Into FP Module Aperture

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.
Remove the fuel level sensor access cover.

Fig 7: Locating Fuel Level Sensor Access Cover
Courtesy of FORD MOTOR CO.

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

Fig 8: Locating Fuel Level Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

Disconnect the fuel level sensor electrical connector.

NOTE: Carefully install the Fuel Tank Sender Unit Wrench to avoid damaging the fuel level sensor when removing the lock ring.

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

NOTE: When installing the fuel level sensor, install a new lock ring and O-ring seal.

Fig 9: Removing Fuel Level Sensor Lock Ring

Courtesy of FORD MOTOR CO.

Install the Fuel Tank Sender Unit Wrench and remove the fuel level sensor lock ring.
Position the fuel level sensor aside, insert the tube from the Fuel Storage Tanker into the fuel level sensor aperture and remove as much of the remaining fuel as possible from the fuel tank.

Fig 10: Locating Tube From Fuel Storage Tanker Into Fuel Level Sensor Aperture
Courtesy of FORD MOTOR CO.