Fuel Pump Module
Fuel Pump Module
Removal and 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.
NOTE: The Fuel Pump (FP) module has a serviceable fuel level sender. For additional information, refer to Fuel Level Sender Fuel Level Sender.
All vehicles
1. Release the fuel system pressure.
2. Disconnect the battery ground cable.
3. Carefully turn the fuel tank filler cap counterclockwise approximately one-fourth turn until the thread disengages and position aside.
4. NOTE: When the fuel tank is completely full, this step will remove approximately one-eighth of the fuel from the fuel tank.
NOTE: The Fuel Draining Hose must be inserted into the fuel tank filler pipe until the fitting on the end of the hose enters into the fuel tank spout, opening the check valve allowing fuel tank drainage. Carefully remove the hose using a gentle agitating motion to avoid detaching the hose from the fitting.
Insert the Fuel Draining Hose into the fuel tank filler pipe.
- Attach the Fuel Storage Tanker to the Fuel Draining Hose and remove as much fuel as possible from the fuel tank and filler pipe, lowering the fuel level below the FP module mounting flange.
Taurus and Sable
5. Remove the rear seat lower cushion.
Taurus X
6. Release the 2 load floor support brackets and position the load floor upward.
All vehicles
7. Remove the FP module access cover.
8. NOTE: Clean the FP module connections, couplings, flange surfaces and the immediate surrounding area of any dirt or foreign material.
Disconnect the FP module electrical connector.
9. NOTE: Place absorbent toweling in the immediate surrounding area in case of fuel spillage.
Disconnect the FP module quick connect coupling(s).
All-Wheel Drive (AWD) vehicles
10. Remove the driveshaft.
Taurus and Sable with a saddle-type tank
11. Disconnect the fuel tank jumper tube-to-fuel tube quick connect coupling.
12. Remove the Evaporative Emission (EVAP) canister.
13. Position a suitable lifting device under the fuel tank.
14. Remove the 2 front fuel tank strap bolts.
- To install, tighten to 35 Nm (26 lb-ft).
15. NOTE: Install suitable caps on the FP module ports to avoid fuel spillage when lowering the front of the fuel tank.
Partially lower the front of the fuel tank for access and remove the FP module shield.
16. Remove the 3 nuts and the FP module shield.
- To install, tighten to 9 Nm (80 lb-in).
17. NOTE: The fuel tank must be placed back into the installed position prior to FP module removal to avoid fuel spillage.
Raise the fuel tank into the installed position and reinstall the 2 fuel tank strap bolts.
All vehicles
18. NOTE: Carefully install the Fuel Tank Sender Unit Wrench to avoid damaging the FP module when removing the lock ring.
Install the Fuel Tank Sender Unit Wrench, remove and discard the FP module lock ring.
19. NOTICE: The Fuel Pump (FP) module must be handled carefully to avoid damage to the float arm.
Carefully lift the FP module out of the fuel tank allowing access and disconnect the FP module internal quick connect coupling(s).
20. Completely remove the FP module from the fuel tank.
21. NOTE: Inspect the surfaces of the FP 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 FP module or fuel tank if the O-ring seal contact area is bent, scratched or corroded.
NOTE: To install, apply clean engine oil to the O-ring seal.
Remove and discard the FP module O-ring seal.
22. NOTE: Make sure to install a new FP module O-ring seal and lock ring.
To install, reverse the removal procedure.
- Make sure the alignment arrows on the fuel pump module and the fuel tank meet before tightening the FP module lock ring.
- Tighten the FP lock ring until it meets the stop tabs on the fuel tank.