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Home › Mercury › 2005 › Montego Base, AWD › Repair and Diagnosis › Engine Performance › Fuel Delivery › Fuel Tank & Fuel Lines › Removal And Installation › Fuel Pump Module › Removal and Installation

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 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 always present and may be ignited. Failure to follow these instructions can result in personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel causing personal injury or a fire hazard.

    All Vehicles 

  1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  3. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  4. Remove the fuel tank filler cap.
  5. Insert a suitable fuel drain tube into the fuel tank filler pipe until it reaches the fuel tank inlet spout.
    6. Fig 1: Inserting Suitable Fuel Drain Hose Into Fuel Tank Filler Pipe
    G03986097Courtesy of FORD MOTOR CO.
    NOTE: When the fuel tank is completely full, this step will remove approximately l/8th of fuel from the fuel tank.
  6. Attach the fuel storage tanker to the fuel drain tube and remove any residual fuel in the fuel tank filler pipe.
    7. CAUTION: The fuel pump module, fuel level sensor and the fuel tank inlet spout are below the fuel level in the fuel tank when the fuel tank is completely filled. Make sure to drain any residual fuel from the fuel tank filler pipe prior to removing the fuel tank filler pipe clamp and hose.
    Fig 2: Removing Clamp Screw Of Fuel Tank Filler Pipe Hose
    G03992080Courtesy of FORD MOTOR CO.
  7. Release the clamp and remove the fuel tank filler pipe hose from the fuel tank inlet spout.
  8. Insert a suitable fuel drain tube into the fuel tank inlet spout.
    Fig 3: Inserting Suitable Fuel Drain Tube Into Fuel Tank Inlet Spout
    G03992081Courtesy of FORD MOTOR CO.
    9. NOTE: When draining a completely full fuel tank, this step will drain most of the fuel from the RH side of the fuel tank and partially drain the LH side of the fuel tank due to the siphoning effect from the fuel crossover tube.
  9. Attach the fuel storage tanker to the fuel drain tube and drain the fuel from the RH side of the fuel tank.

    10. Five Hundred, Montego 

  10. Remove the rear lower seat cushion.
    • Release the latches and pull upward on the rear lower seat cushion and remove.
      Fig 4: Identifying Lower Seat Cushion Releasing Latch
      G03945904Courtesy of FORD MOTOR CO.

    11. Freestyle 

  11. Position the second row seat forward.
  12. Remove the bolt and the LH third row rear seat load floor support.
    • To install, tighten to 17 Nm (13 lb-ft).
  13. Remove the LH second row seat belt anchor bolt.
    • To install, tighten to 30 Nm (20 lb-ft).

    14. All vehicles 

  14. Position any carpet and/or insulation covering the fuel pump module access cover aside.
  15. Remove the fuel pump module access cover.
  16. Clean the surrounding area of the fuel pump module mounting flange and the quick connect couplings with compressed air.
  17. Disconnect the fuel pump module electrical connector.
  18. Disconnect the fuel supply tube-to-fuel pump module quick connect coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  19. Disconnect the fuel vapor tube-to-fuel pump module quick connect coupling from the top of the fuel pump module. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  20. Install the special tool and remove the fuel pump module lock ring.
    Fig 5: Removing Fuel Pump Module Lock Ring
    G03924145Courtesy of FORD MOTOR CO.
  21. Carefully lift the fuel pump module out of the fuel tank allowing access to disconnect the quick connect couplings.
  22. Disconnect the fuel supply tube-to-fuel pump module quick connect coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  23. Disconnect the fuel vapor tube-to-fuel pump module quick connect coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
    24. CAUTION: The fuel pump module must be handled carefully to avoid damage to the float arm.
    CAUTION: Place absorbent pads on the floor pan in case of spills. Carefully remove fuel pump module from the fuel tank to avoid fuel spillage inside the vehicle.
  24. Completely remove the fuel pump module from the fuel tank.
    25. CAUTION: Inspect the surfaces of the fuel pump 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 fuel pump module or fuel tank if the O-ring seal contact area is bent, scratched or corroded.
    CAUTION: Make sure to install a new fuel pump module O-ring seal and lock ring.
    NOTE: To install, apply clean engine oil to the O-ring seal.
  25. Remove the fuel pump module O-ring seal.
  26. To install, reverse the removal procedure.
    • Make sure the alignment arrows on the fuel pump module and the fuel tank meet before tightening the fuel pump module lock ring.
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