2004 Lincoln LS Workshop Manual

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1 SECTION : Fuel System 2004 Lincoln LS Workshop Manual REMOVAL AND INSTALLATION Procedure revision date: 01/23/2004 Fuel Tank and Filler Pipe Printable View (541 KB) Special Tool(s) Fuel Drain Hose Fuel Storage Tanker 14-R3202 or equivalent Fuel Sender Wrench 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, resulting in possible 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. 1. If the fuel tank, fuel transfer pump or fuel delivery module is being removed drain the fuel tank. For additional information, refer to Fuel Tank Draining in this section. 2. If the fuel tank is being removed, remove the driveshaft. For additional information, refer to Section Remove the parts in the order indicated in the following illustrations and tables. To remove individual parts, only carry out the listed steps: Part Steps Fuel filler pipe 1-5 Fuel tank, 8-17 Fuel transfer pump Fuel delivery module 18-27

2 Item Part Number Description Fuel filler cap 2 Fuel filler pipe mounting screws 3 Fuel filler pipe mounting bolt 4 Fuse hose-to-filler pipe clamp 5 Fuel filler pipe Fuel hose-to-tank clamp Fuel hose and clamps 8 9C291 Fuel tube shield 9 Fuel supply quick connect fitting 10 9J274 Vapor tube fitting 11 N Fuel tank strap mounting bolt 12 N Fuel tank strap mounting bolt Fuel tank strap Fuel tank strap 15 14A24 Fuel tank electrical connector 1 9J724 Vapor tube quick connect fitting Fuel tank

3 Item Part Number Description 18 14A44 Fuel transfer pump electrical connector 19 Fuel delivery tube quick connect fitting 20 14A44 Fuel delivery module electrical connector 21 9A307 Fuel transfer pump lock ring 22 9A309 Fuel transfer pump 23 Fuel crossover hose quick connect fittings Fuel transfer pump gasket 25 9A307 Fuel delivery module lock ring 2 9A309 Fuel delivery module Fuel delivery module gasket 4. To install, reverse the removal procedure. 5. Fill the fuel tank.. Turn the ignition key to the ON position to pressurize the fuel system. 7. Visually inspect the fuel system for leaks. Item 5: Fuel Filler Pipe 1. Remove the right rear well inner fender splash shield. 2. CAUTION: Some fuel will remain in the filler pipe after draining the fuel tank. Carefully drain the filler pipe into an approved container. Loosen the clamp at the fuel tank filler pipe and remove the filler pipe.

Item 8: Fuel Tube Shield 1. Position the fuel tube shield aside. 1. Remove the pin-type retainers. 2. Remove the bolt. Item 12: Fuel Tank Strap Mounting Bolt 1.

Partially lower the fuel tank and disconnect the vapor tube. Item 23: Fuel Crossover Hose Quick Connect Fitting 1.

4 Item 8: Fuel Tube Shield 1. Position the fuel tube shield aside. 1. Remove the pin-type retainers. 2. Remove the bolt. Item 12: Fuel Tank Strap Mounting Bolt 1. Remove the bolts and the heat shield. 2. Position a suitable lifting device to support the fuel tank. Item 1: Vapor Tube Quick Connect Fitting 1. Partially lower the fuel tank and disconnect the vapor tube. Item 23: Fuel Crossover Hose Quick Connect Fitting 1. NOTE: The routing of the internal fuel crossover hoses 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 hose quick connect fittings.

Item 2: Fuel Delivery Module 1. 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 line.

5 Item 2: Fuel Delivery Module 1. 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 line. Then remove the fuel delivery module and crossover lines as an assembly, using the non-conductive material to pull the crossover lines through the gas tank. Item 2: Fuel Delivery Module 1. NOTE: Install the fuel delivery module and crossover lines as an assembly. Attaching the non-conductive material to the crossover lines, pull the crossover lines through the gas tank to install the fuel delivery module. Item 25: Fuel Delivery Module Lock Ring 1. Using the special tool, install the fuel delivery module lock ring. Item 23: Fuel Crossover Hose Quick Connect Fittings 1. NOTE: Make sure that the fuel crossover hoses are routed correctly. Raise the fuel transfer pump and connect the fuel crossover hose quick connect fittings. Item 22: Fuel Transfer Pump 1. Partially install the fuel transfer pump.

6 Item 21: Fuel Transfer Pump Lock Ring 1. Using the special tool, install the fuel transfer pump lock ring. Item 8: Fuel Tube Shield 1. Install the fuel tube shield. 1. Install the pin type retainers. 2. Install the bolt.

REMOVAL AND INSTALLATION

310-00-1 Fuel System 310-00-1 REMOVAL AND INSTALLATION Fuel Tank and Filler Pipe Special Tool(s) Fuel Tank Drain Hose 310-F013 2. NOTE: Steps 2 through 5 are only necessary if servicing the fuel tank or