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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.

All vehicles 

  1. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  2. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  3. Remove the rear seat lower cushion. For additional information, refer to REMOVAL AND INSTALLATION .
  4. Remove the Fuel Pump (FP) module access cover.
    5. NOTE: Clean the FP  module connections, couplings, flange surfaces and the immediate surrounding area of any dirt or foreign material.
  5. Disconnect the FP  module electrical connector.
  6. Disconnect the fuel tank wiring harness electrical connector.
  7. Disconnect the Fuel Tank Pressure (FTP) sensor electrical connector.
    8. NOTE: Place absorbent toweling in the immediate surrounding area in case of fuel spillage.
  8. Disconnect the fuel tank jumper tube-to-FP  module quick connect coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  9. Attach the Fuel Storage Tanker tube to the FP  module outlet fitting and remove one fourth (approximately 5 gallons) of the fuel from a completely full tank, lowering the fuel level below the FP  module mounting flange.
    Fig 1: Locating Fuel Storage Tanker Tube
    G06261696Courtesy of FORD MOTOR CO.

    All-Wheel Drive (AWD) vehicles 

  10. Remove the Evaporative Emission (EVAP) canister. For additional information, refer to EVAPORATIVE EMISSIONS .
  11. Remove the driveshaft. For additional information, refer to DRIVESHAFT .
  12. Position the Powertrain Lift under the fuel tank.
  13. Loosen the 2 rear fuel tank strap bolts.
    • Calculate the correct torque wrench setting for the following torque. Refer to the appropriate Torque Wrench Adapter Formula.
    • To install, use a torque adapter and tighten to 35 N.m (26 lb-ft).
  14. Remove the 2 front fuel tank strap bolts.
    • To install, tighten to 35 N.m (26 lb-ft).
    15. NOTE: Install a suitable cap on the FP  module port to avoid fuel spillage when lowering the front of the fuel tank.
  15. Partially lower the front of the fuel tank to access the FP  module shield nuts.
  16. Remove the 3 nuts and the FP  module shield.
    • To install, tighten to 9 N.m (80 lb-in).
    17. NOTE: The fuel tank must be placed back into the installed position prior to FP  module removal to avoid fuel spillage.
  17. Raise the fuel tank into the installed position and reinstall the 2 front fuel tank strap bolts.

    All vehicles 

    18. NOTE: Carefully install the Fuel Tank Sender Unit Wrench to avoid damaging the FP  module when removing the lock ring.
    Fig 2: Locating FP Module Lock Ring
    G06261687Courtesy of FORD MOTOR CO.
  18. Install the Fuel Tank Sender Unit Wrench, remove the FP  module lock ring.

    AWD vehicles 

    19. NOTE: The Fuel Pump (FP) module must be handled carefully to avoid damage to the float arm.
  19. Carefully lift the FP  module out of the fuel tank allowing access and disconnect the FP  module internal quick connect coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .

    All vehicles 

    20. NOTE: The Fuel Pump (FP) module must be handled carefully to avoid damage to the float arm.
    NOTE: The FP  module will have residual fuel remaining internally, drain into a suitable container.
  20. Completely remove the FP  module from the fuel tank.
    21. 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.
  21. Remove and discard the FP  module O-ring seal.
    22. NOTE: Make sure to install a new FP  module O-ring seal.
    NOTE: To install, apply clean engine oil to the O-ring seal.
  22. To install, reverse the removal procedure.
    • Make sure the aligN.ment arrows on the fuel pump 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.
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