Fuel Pump Assembly: Installation

WARNING: Do not smoke, carry lighted tobacco or have an 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 may result in serious 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 component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.

WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

1.

NOTE: The FP module must be handled carefully to avoid damage to the float arm.

NOTE: Inspect the mating surfaces of the FP module flange and fuel tank O-ring seal contact surfaces. Wipe clean with a lint free towel. Install a new FP module or fuel tank if the O-ring seal contact area is bent, scratched or corroded.

NOTE: Sweep the float arm to ensure freedom of travel.

NOTE: Make sure to install a new FP module O-ring seal.

Install a new O-ring seal.

2.

Loosely install a 12" (minimum length) zip-tie to the internal fuel tube at the quick connect coupling. Leave the tail of the zip tie on to allow the tube to be retrieved while the FP module is being installed.

Courtesy of FORD MOTOR COMPANY

3.

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

Install the FP module by inserting the float rod through the Fuel Tank opening. Connect the transfer tube quick connect coupling at the bottom of the FP module. Then, use the zip tie to help retrieve and connect the internal fuel tube to the FP module as it is installed into the fuel tank. For additional information, REFER to Fuel System - General Information . Remove the zip tie.

4.

NOTE: Install a new lock ring if it is bent, damaged or corroded.

NOTE: Carefully install the Fuel Tank Sender Unit Wrench to avoid damaging the FP module when tightening the lock ring.

Install the Fuel Tank Sender Unit Wrench and tighten the fuel tank lock ring by turning clockwise.

5.

Install the fuel tank. Refer to Fuel Tank .