Fuel Pump Module: Removal

WARNING: Do not smoke or carry lighted tobacco or 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 can result in 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 components. Highly flammable mixtures are present and may be ignited. Failure to follow these instructions can result in personal injury.

WARNING: This procedure involves fuel handling. Be prepared for spillage at all times and always observe fuel handling precautions. Failure to follow these instructions can result in personal injury.

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 .
Insert the special tool into the fuel tank filler pipe until it reaches the fuel tank spout.

Fig 1: Inserting Special Tool (310-102) Into Fuel Tank Filler Pipe
Courtesy of FORD MOTOR CO.
Attach the Fuel Storage Tanker to the Fuel Drain Hose and remove any residual fuel in the fuel tank filler pipe.
Remove the rear seat bottom and any insulation padding covering the fuel transfer pump access covers. For additional information, refer to SEATING .
Remove the fuel pump module and fuel transfer pump access covers.

Fig 2: Locating Fuel Pump Access Covers
Courtesy of FORD MOTOR CO.
Disconnect the electrical connector from the fuel transfer pump module.

Fig 3: Locating Electrical Connector At Fuel Transfer Pump Module
Courtesy of FORD MOTOR CO.
Loosen the right fuel tank support strap approximately one inch.
Loosen the left fuel tank support strap approximately one inch.
Using the special tool, remove the fuel transfer pump lock ring.

Fig 4: Removing/Installing Fuel Transfer Pump Lock Ring Using Special Tool
Courtesy of FORD MOTOR CO.
Disconnect the electrical connector on the fuel pump module.

Fig 5: Disconnecting Electrical Connector On Fuel Pump Module
Courtesy of FORD MOTOR CO.
Using the special tool, remove the fuel pump module lock ring.

Fig 6: Removing/Installing Fuel Transfer Pump Lock Ring Using Special Tool
Courtesy of FORD MOTOR CO.

NOTE: The routing of the internal fuel crossover tubes is critical to correct fuel system operation. Note the routing of the internal fuel crossover hoses at this time.

Partially raise the fuel transfer pump and disconnect the internal fuel crossover tube quick connect couplings.
Disconnect the fuel pump module tube quick connect coupling from the fuel pump module and position aside.

CAUTION: Drain the remaining fuel from the delivery module into the fuel tank prior to removal.

Before removal, attach a non-conductive material to the crossover tubes. Then remove the fuel pump module and crossover tubes as an assembly, using the non-conductive material to pull the crossover lines through the gas tank.
- Remove and discard the fuel pump module gasket.
  
  Fig 7: Pulling Crossover Lines Through The Gas Tank
  Courtesy of FORD MOTOR CO.