Fuel Tank Unit: Service and Repair

NOTE: Fuel supply lines remain pressurized for long periods of time after the engine is shut down. This pressure must be relieved before the fuel system is serviced. The fuel system on these vehicles are depressurized by disconnecting the inertia fuel shutoff switch and cranking the engine for a minimum of 15 seconds.

NOTE: On some vehicles, fuel tank sending unit is unavailable as a separate unit. On those vehicles, to replace the sending unit, replace the entire pump.

Fuel Tank Installation:

REMOVAL
1. Remove fuel tank. Refer to Fuel Tank/Service and Repair.
2. Remove fuel tank to bench. Remove any dirt that has accumulated around the fuel pump attaching flange so that it will not enter the fuel tank during fuel pump removal.
3. Turn the fuel tank sending unit locking retainer ring counterclockwise with the fuel tank lockring wrench T90T-9275-A or fuel tank sender wrench T86T-9275-A and remove fuel tank sending unit locking retainer ring.
4. Unscrew the (6) M6 fasteners and remove the fuel delivery module from the fuel tank.

INSTALLATION
1. If necessary, install the fuel tank sending unit and two screws. Connect spade connector.
2. Clean the fuel pump mounting flange and the fuel tank mounting surfaced and groove in fuel tank sending unit locking retainer ring.
3. 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 and install it in the fuel ring groove.
4. Install fuel pump and sending unit assembly carefully to make sure that the filter is not damaged. Be sure that the locating keys are in keyways and the fuel pump mounting gasket remains in place.
5. Hold the fuel sending unit and fuel pump mounting gasket in place. Install and rotate the fuel tank sending unit locking retainer ring clockwise using fuel tank lockring wrench T90T-9275-A.
6. Install the replacement unit and hand start the (6) M6 fasteners. Torque fasteners to 9-12 Nm (7-9 lb ft).