Removal and Installation

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: 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.

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: The Fuel Pump (FP) module has a serviceable fuel level sender. For additional information, refer to FUEL LEVEL SENDER .

Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Remove the FP module access cover.

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

Disconnect the FP module electrical connector.

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

Disconnect the fuel tank jumper tube-to- FP module quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
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 1: Locating FP Module Outlet Fitting
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.

Using the Fuel Tank Sender Unit Wrench, remove the FP module lock ring.
- Discard the FP module lock ring.
  
  Fig 2: Removing FP Module Lock Ring
  Courtesy of FORD MOTOR CO.

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

Carefully lift the FP module out of the fuel tank allowing access and disconnect the internal fuel tube-to- FP module quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .

NOTE: Some residual fuel may remain in the FP module. Carefully drain into a suitable container.

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.

NOTE: To install, apply clean engine oil to the O-ring seal.

Remove and discard the FP module O-ring seal.

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

To install, reverse the removal procedure.
- Make sure the alignment arrows on the FP module and the fuel tank meet before tightening the FP module lock ring.
- Tighten the FP lock ring until it meets the stop tabs on the fuel tank.