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: 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: 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: 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.

3.7L, 5.0L (4V) and 5.4L (4V) vehicles

Release the fuel pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING & CABLES article.

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

Fig 1: View Of Supplemental Refueling Adapter

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-eighth tank of fuel from a completely full fuel tank and the majority of any residual fuel from the fuel tank filler pipe. Also the fuel in the fuel tank will be below the Fuel Pump (FP) module mounting flange for FP module removal without fuel spillage.

Attach the Fuel Storage Tanker to the drain tube and remove one-eighth of the fuel (approximately 2 gallons) from a completely full tank, lowering the fuel below the FP module mounting flange.
3.7L and 5.0L (4V) vehicles
Lower the fuel tank.
1. Lift the vehicle. For additional information, refer to JACKING & LIFTING article.
2. Support the fuel tank.
3. Remove the fuel tank strap bolts.
  - Tighten to 52 Nm (38 lb-ft).
4. By hand, reinstall the fuel tank strap bolts three full turns.
5. Remove the fuel tank support.
6. Lower the vehicle.
3.7L, 5.0L (4V) and 5.4L (4V) vehicles
Remove the rear seat cushion. For additional information, refer to SEAT SYSTEM article.
Remove the FP module and fuel level sensor access covers and position.

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 pads in the general work area in case of fuel spillage.

Disconnect the rear fuel tube-to-FP module quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
5.4L (4V) Vehicles

NOTE: Carefully install the Fuel Tank Sender Unit Socket to avoid damaging the FP module when removing the lock ring.

Fig 2: Removing FP Module Retaining Lock Ring Using Fuel Tank Sender Unit Socket

Courtesy of FORD MOTOR CO.

Using the Fuel Tank Sender Unit Socket, remove the FP module lock ring.
3.7L and 5.0L (4V) vehicles

NOTE: Carefully install the Fuel Tank Sender Unit Socket to avoid damaging the FP module when removing the lock ring.

Fig 3: Removing FP Module Lock Ring Using Fuel Tank Sender Unit Socket

Courtesy of FORD MOTOR CO.

Using the Fuel Tank Sender Unit Socket, remove the FP module lock ring.
3.7L, 5.0L (4V) and 5.4L (4V) vehicles

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

NOTE: Completely draining the LH saddle of the fuel tank will lower the fuel level in the RH saddle of the fuel tank, allowing the removal of the fuel level sensor without fuel spillage.

Position the FP module. Using the Fuel Storage Tanker, completely drain the remaining fuel from the LH saddle of 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: Clean the fuel level sensor connections, flange surfaces and the immediate surrounding area of any dirt or foreign material.

Disconnect the fuel level sensor electrical connector.
5.4L (4V) vehicles

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

Fig 4: Removing Fuel Level Sensor Retaining Lock Ring Using Fuel Tank Sender Unit Socket

Courtesy of FORD MOTOR CO.

Using the Fuel Tank Sender Unit Socket, remove the fuel level sensor lock ring.
3.7L and 5.0L (4V) vehicles

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

Fig 5: Removing Fuel Level Sensor Lock Ring Using Fuel Tank Sender Unit Socket

Courtesy of FORD MOTOR CO.

Using the Fuel Tank Sender Unit Socket, remove the fuel level sensor lock ring.
3.7L, 5.0L (4V) and 5.4L (4V) vehicles

NOTE: The fuel level sensor must be handled carefully to avoid damage to the float arm.

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

NOTE: Drain any residual fuel in the fuel level sensor into a suitable container.

Completely remove the fuel level sensor from the fuel tank.

NOTE: Inspect the surfaces of the fuel level sensor 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 fuel level sensor or fuel tank if the O-ring seal contact area is bent, scratched or corroded.

Remove and discard the fuel level sensor O-ring seal.
- To Install, apply clean engine oil to the new O-ring seal.

NOTE: Make sure to install a new FP module and fuel level sensor O-ring seals.

NOTE: Make sure the alignment tabs on the FP module and the fuel level sensor meet with the slots on the fuel tank before tightening the lock rings.

To install, reverse the removal procedure.

Tighten the lock rings until they meet the stop tabs on the fuel tank.