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.

All fuel tanks

Remove the fuel tank. For additional information, refer to FUEL TANK .
127L (33.5 gal) fuel tank
Remove the 4 nuts and the Fuel Pump (FP) module cover.
- To install, tighten to 9 Nm (80 lb-in).
  
  Fig 1: Locating Nuts And Fuel Pump (FP) Module Cover
  Courtesy of FORD MOTOR CO.
Disconnect the return fuel tube-to- FP module quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
All fuel tanks
Disconnect the Fuel Tank Pressure (FTP) sensor and vapor tube assembly-to- FP module quick connect coupling and the supply fuel tube-to-FP module quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
Using the Fuel Tank Sender Unit Wrench, remove the FP lock ring.

Fig 2: Removing FP Lock Ring
Courtesy of FORD MOTOR CO.

106L (28 gal) fuel tank

NOTE: Carefully remove the Fuel Pump (FP) assembly to avoid damaging the fuel level sensor.

NOTE: If the FP does not clear the FP mounting flange on the fuel tank, the use of a screwdriver may be necessary.

Remove the FP and FP O-ring seal.
- If necessary, insert a screwdriver into the empty FP rod hole and slightly pull the screwdriver inboard until the base of the FP clears the FP mounting flange.
- Discard the FP O-ring seal.
  
  Fig 3: Removing FP O-Ring Seal
  Courtesy of FORD MOTOR CO.
  
  127L (33.5 gal) fuel tank

NOTE: Carefully remove the Fuel Pump (FP) assembly to avoid damaging the fuel level sensor.

NOTE: Note the location of the FP alignment tabs.

Remove the FP module assembly.
- Remove and discard the O-ring seal.
  All fuel tanks
To install, reverse the removal procedure.