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 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 present and may be ignited. 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: Identifying Special Tool
Courtesy of FORD MOTOR CO.
Attach the fuel storage tanker to the fuel drain hose and remove any residual fuel in the fuel in the fuel tank filler pipe.
Remove the rear seat bottom and any insulation padding covering the fuel pump module and the fuel transfer pump access covers. For additional information, refer to SEATING .
Remove the fuel pump module and the fuel transfer pump access covers.

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

Fig 3: Locating Fuel Transfer Pump Module Electrical Connector
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: Identifying Special Tool
Courtesy of FORD MOTOR CO.
Disconnect the electrical connector on the fuel pump module.

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

Fig 6: Identifying 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.
- Remove and discard the fuel transfer pump O-ring seal.
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 O-ring seal.
  
  Fig 7: Locating Fuel Pump Module Tube Quick Connect Coupling
  Courtesy of FORD MOTOR CO.