REMOVAL AND INSTALLATION

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Reginald Daniels
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1 Fuel System REMOVAL AND INSTALLATION Fuel Tank and Filler Pipe Special Tool(s) Fuel Tank Drain Hose 310-F NOTE: Steps 2 through 5 are only necessary if servicing the fuel tank or fuel pump module. Relieve the fuel system pressure. For additional information, refer to Fuel System Pressure Release in this section. 3. Disconnect the battery ground cable. For additional information, refer to Section Gallon Hand-Operated Fuel Tanker or equivalent 4. Disconnect the fuel tank filler pipe from the fuel tank. Wrench, Fuel Tank Sender Unit WARNING: The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery ground cable from the battery to minimize the possibility of an electrical spark occurring, possibly causing a fire or explosion if fuel vapor or liquid fuel are present in the area. Failure to follow these instructions can result in personal injury. 5. NOTE: Follow the operating instructions supplied by the equipment manufacturer. Attach the fuel draining hose to the storage tanker and insert the hose through the disconnected filler pipe hose. Siphon the fuel from the fuel tank. 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 can be ignited. Failure to follow these instructions can result in personal injury. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section Copyright 2003, Ford Motor Company Last updated: 9/22/2005

2 Fuel System Remove the parts in the order indicated in the following illustrations and tables. To remove individual parts, only carry out the listed steps: Part Fuel filler pipe 1, 2, 4-6 Fuel tank 5, 7-19 Steps To remove individual parts, only carry out the listed steps: (Continued) Part Fuel pump module 5, 7-23 Fuel tanks support strap 18 Steps

3 Fuel System Item Part Number Description Item Part Number Description Fuel filler cap 2 Fuel filler pipe hose clamp 7 Vapor tube quick connect fitting (part of 9C047) 8 Fuel tube quick connect 3 Fuel filler pipe hose clamp fitting (part of 9S278) Fuel filler pipe hose Fuel filler pipe vent tube 9 Fuel vapor vent control tube assembly valve electrical connector Fuel filler pipe (Continued) (Continued)

4 Fuel System Item Part Number Description Item Part Number Description 10 Fuel delivery module Fuel tank assembly electrical connector 20 9J279 Fuel supply and vapor 11 Vapor tube quick connect assembly fitting (part of 9C047) 21 9C385 Fuel pump module locking 12 Fuel tube quick connect ring fitting (part of 9S278) 22 9H307 Fuel pump module 13 W Fuel tank skid plate nuts (4 req d) Fuel pump module O-ring 14 9A147 Fuel tank skid plate seal 15 W Fuel tank support strap bolt-to-no. 4 crossmember 7. To install, reverse the removal procedure. 16 W Fuel tank support strap bolt-to-no. 3 crossmember Fuel tank support strap Fuel tank support strap Item 1: Fuel Filler Cap 1. Remove the fuel filler cap. 2. Remove the screws. Item 2: Fuel Filler Pipe Hose Clamp Removal Note 1. Disconnect and set aside the fuel filler pipe.

5 Fuel System Items 5, 7, 8, 11 and 22: Quick Release Fitting Items 12 and 20: Fuel Tube Quick Connect Fitting 1. CAUTION: Fuel injection equipment is 1. WARNING: Fuel in the fuel system manufactured to very precise tolerances and remains under high pressure even when the fine clearances. It is therefore essential that engine is not running. Before servicing or absolute cleanliness is observed when disconnecting any of the fuel lines or fuel working with these components. Always system components, the fuel system pressure install blanking plugs to any open orifices or must be relieved to prevent accidental tubes. spraying of fuel, causing personal injury or CAUTION: When reusing liquid or a fire hazard. vapor tube connectors, make sure to use CAUTION: Fuel injection equipment is compressed air to remove any foreign manufactured to very precise tolerances and material from the connector retaining clip fine clearances. It is therefore essential that area before separating from the tube. absolute cleanliness is observed when NOTE: If the fuel tube retainer clip is broken working with these components. Always or damaged, install a new clip using a suitable install blanking plugs to any open orifices or fuel line disconnect tool to separate the tubes. retaining clip legs. Once the retainer legs have CAUTION: When reusing liquid or been separated, lift the clip out of the connector vapor tube connectors, make sure to use housing, lifting from the stamped side of the compressed air to remove any foreign connector body. material from the connector retaining clip Disconnect the quick release fitting. area before separating from the tube. Push the connector toward the tube to release pressure. Press the quick release fitting button and pull the fuel tube to disconnect. Press the tab corners to release the locking tab. 2. Pull the locking tab to the release position.

6 Fuel System Disconnect the quick connect fitting. Push the fitting toward the tube to release pressure. Press the tab corners to release the fitting. Disconnect the quick connect fitting. 2. NOTE: The fuel pump module must be handled carefully to avoid damage to the float arm and the filter. Remove the fuel pump module. Items 23-21: Fuel Pump Module Locking Ring, Fuel Pump Module and O-ring Seal Items 15 and 16: Fuel Tank Support Strap Bolts 1. Lubricate the fuel pump module O-ring seal 1. Use a suitable jack to support the fuel tank. with clean engine oil prior to installation. 2. NOTE: The fuel pump module must be handled carefully to avoid damage to the float arm and the filter. Install the fuel pump module. 3. Using the special tool, install the fuel pump module locking ring. Item 18: Fuel Tank Support Strap Removal Note 1. NOTE: Some two-piece driveshafts will have a shim between the crossmember and the center bearing. If this shim is present then the following step must be carried out. Remove the driveshaft center bearing bolts and position and support the driveshaft aside. Item 21: Fuel Pump Module Locking Ring 1. Using the special tool, remove the fuel pump module locking ring.

7 Fuel System Item 18: Fuel Tank Support Strap 1. NOTE: Some two-piece driveshafts will have a shim between the crossmember and the center bearing. If this shim is present then the following step must be carried out. Position the driveshaft in place and install the driveshaft center bearing with shim bolts. To install, tighten to 48 Nm (35 lb-ft). Items 11, 8, 7 and 5: Quick Connect Fitting 1. CAUTION: Fuel injection equipment is Items 20 and 12: Fuel Tube Quick Connect manufactured to very precise tolerances and Fitting fine clearances. It is therefore essential that 1. CAUTION: Make sure the quick absolute cleanliness is observed when connect fitting clicks into place when working with these components. Always installing the tube. To make sure that the install blanking plugs to any open orifices or quick connect fitting is fully seated, pull on tubes. the tube. CAUTION: When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube. CAUTION: Make sure the quick release fitting clicks into place when installing the tube. To make sure that the quick release fitting is fully seated, pull on the tube. NOTE: If the fuel tube retainer clip is broken or damaged, install a new clip using a suitable fuel line disconnect tool to separate the retaining clip legs. Once the retainer legs have been separated, lift the clip out of the connector housing, lifting from the stamped side of the connector body. NOTE: Apply clean engine oil to the end of the tube before connecting the fitting. Connect the quick release fitting. NOTE: Apply clean engine oil to the end of the tube before connecting the fitting. Connect the tube into the quick connect fitting. 2. Press the locking tab down into the locked position.

8 Fuel System Item 1: Fuel Filler Cap 2. Install the fuel filler cap. 1. Install the screws.

FUEL TANK DRAINING. Special Tool(s) Special Tool(s)

FUEL TANK DRAINING. Special Tool(s) Special Tool(s) FUEL TANK DRAINING Special Tool(s) Zoom Special Tool(s) WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures