Removal And Installation

WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. 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 always 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 .
Release the fuel tank filler cap and position aside.

Fig 1: Locating Fuel Tank Filler Cap

Courtesy of FORD MOTOR CO.

Insert a suitable fuel drain hose into the fuel tank filler pipe until it reaches the fuel tank inlet tube.

Fig 2: Inserting Suitable Fuel Drain Hose Into Fuel Tank Filler Pipe

Courtesy of FORD MOTOR CO.

CAUTION: The fuel pump (FP) module and fuel level sensor will be below the fuel level in the tank when the tank is full. Make sure to drain 1/8 of the fuel capacity through the filler pipe prior to removing the pumps or fuel spillage will occur.

NOTE: When draining a completely full fuel tank, this step will remove approximately 1/8 of fuel from the LH side of the fuel tank.

Attach the fuel storage tanker to the fuel drain hose and remove as much fuel as possible from the fuel tank filler pipe.
Remove the rear seat cushion. For additional information, refer to SEATING .
Position any insulation padding covering the FP module access cover aside.
Remove the FP module access cover and position aside.

Fig 3: Locating FP Module Access Cover

Courtesy of FORD MOTOR CO.

NOTE: 4.0L and 4.6L FP modules shown, 5.4L FP module similar.

Disconnect the FP module electrical connector.

Fig 4: Locating FP Module Electrical Connector

Courtesy of FORD MOTOR CO.

NOTE: Place absorbent pads in the general work area in case of fuel spillage.

Disconnect the rear fuel supply tube-to-FP module quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .

Fig 5: Locating Quick Connect Coupling On FP Module

Courtesy of FORD MOTOR CO.

Using the special tool, remove and discard the FP module retaining lock ring.

Fig 6: Identifying Special Tool For FP Module Retaining Lock Ring

Courtesy of FORD MOTOR CO.

CAUTION: The FP module must be handled carefully to avoid damage to the float arm, filter and the convolute hoses.

Carefully lift the FP module out of the fuel tank enough to access the fuel crossover tube-to-FP module quick connect coupling.
Disconnect the fuel crossover tube-to-FP module quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .

Fig 7: Locating Cross-Over Fuel Tube Quick Connect Coupling

Courtesy of FORD MOTOR CO.

Completely remove the FP module from the fuel tank.
Remove the FP module O-ring seal.