Fuel Tank Unit: Service and Repair

WARNING: Fuel supply tubes remain pressurized for long periods of time after the engine is shut down. This pressure must be relieved before the fuel system is serviced.

Refer to Fuel Pressure Release/Service and Repair.




REMOVAL
1. Remove the fuel tank. Note whether mid-ship or aft / axle.
2. Position fuel tank on a work bench and remove any dirt that has accumulated around the fuel tank sending unit and pump so that it will not enter the fuel tank.
3. Turn the fuel pump locking retainer ring counterclockwise with Fuel Tank Sender Wrench D84P-9275-A or equivalent and remove fuel pump locking retainer ring.

NOTE: ON Cutaway vehicles, the fuel tank sending unit and fuel pump is held in place by bolts.


4. Remove the fuel tank sending unit and pump from the fuel tank.
5. Remove fuel pump mounting gasket and discard.

INSTALLATION
1. Clean the fuel pump mounting flange and the fuel tank mounting surface and groove in the fuel pump mounting gasket.
2. Put a light coating of Premium Long-Life grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B on a new fuel pump mounting gasket to hold it in place during assembly. Install it in the fuel ring groove.
3. Install fuel tank sending unit and pump carefully to make sure that the fuel filter is not damaged. Be sure that the tabs of the fuel tank sending unit and pump are positioned into slots of the fuel tank. Make sure ring remains in place.
4. Hold the fuel tank sending unit and pump and fuel pump mounting gasket in place; install and rotate the fuel pump locking retainer ring clockwise until the stop is against the retainer ring tab.
5. On Cutaway vehicles, tighten the fuel tank sending unit and fuel pump retaining bolts to 9-11 N.m (80-97 lb in).
6. Install fuel tank.