Fuel Pump Module: Installation

NOTE: Install the fuel pump module and crossover tubes as an assembly.

Attaching the non-conductive material to the crossover tubes, pull the crossover tubes through the gas tank to install the fuel pump module.

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.

NOTE: Make sure the alignment arrows on the fuel pump module and the fuel tank meet before tightening the fuel pump module lock ring.

NOTE: Apply clean engine oil to the O-ring seal.

Using the special tool, install the fuel pump module and lock ring.
- Install a new fuel pump module lock ring and O-ring seal.
- To install, tighten the fuel pump module lock ring until the lock tabs are seated against the stops.
  
  Fig 1: Identifying Special Tool
  Courtesy of FORD MOTOR CO.

NOTE: Make sure that the fuel crossover tubes are routed correctly.

Partially raise the fuel transfer pump and connect the internal fuel crossover hose quick connect couplings.

CAUTION: Inspect the surfaces of the fuel transfer pump 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 transfer pump or fuel tank if the O-ring seal contact area is bent, scratched or corroded.

NOTE: Make sure the alignment arrows on the fuel transfer pump and the fuel tank meet before tightening the fuel pump module lock ring.

NOTE: Apply clean engine oil to the O-ring seal.

Using the special tool, install the fuel transfer pump and lock ring.
- Install a new fuel transfer pump lock ring and O-ring seal.
- To install, tighten the fuel transfer pump lock ring until the lock tabs are seated against the stops.
  
  Fig 2: Identifying Special Tool
  Courtesy of FORD MOTOR CO.
Connect the electrical connector on the fuel transfer pump.

Fig 3: Locating Fuel Transfer Pump Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the electrical connector on the fuel pump module.

Fig 4: Locating Fuel Pump Module Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the fuel tube quick connect coupling on the fuel pump module.

Fig 5: Locating Fuel Tube Quick Connect Coupling On Fuel Pump Module
Courtesy of FORD MOTOR CO.
Install the fuel pump module and fuel transfer pump access covers.

Fig 6: Locating Fuel Pump Access Cover
Courtesy of FORD MOTOR CO.
Install the rear seat bottom and any insulation padding covering the access covers. For additional information, refer to SEATING .
Tighten the 2 fuel tank support strap bolts.
- Tighten to 35 Nm (26 lb-ft).
Connect the battery ground cable. For additional information, refer to BATTERY MOUNTING AND CABLES .
Turn the ignition key to the ON position to pressurize the fuel system.
Visually inspect the fuel system for leaks.