Place vehicle on hoist but do not raise.
Install Multiport Fuel Injection (MFI) Fuel Pressure Gauge T80L-9974-B and depressurize fuel system as outlined in Fuel System Pressure Relief under Service Procedures.
Drain Fuel from fuel tank through fuel tank filler pipe as outlined.
Raise vehicle on hoist. Refer to Section 00-02.
Remove Fuel Tank as outlined and move to bench.
Remove any dirt that has accumulated around fuel pump module retaining flange so that it will not enter fuel tank during removal and installation.
Turn fuel pump locking retainer ring counterclockwise using Fuel Tank Sender Wrench T74P-9275-A and remove fuel pump locking retainer ring.
Pull fuel pump module sender plate up out of tank until locking tabs for module are accessible. Squeeze both locking tabs together and remove fuel pump (FP) module from fuel tank.
Remove O-ring seal and discard.
Clean the fuel pump module mounting flange, fuel tank mounting surface and seal ring groove.
Apply a light coating of Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-BA on a new O-ring seal to hold it in place during assembly and install it in seal ring groove.
Install the fuel pump module carefully into the fuel tank to make sure that the filter, hoses and float rod are not damaged or binding. Align the fuel pump module and the fuel tank retainer axially and push the fuel pump module into the fuel tank retainer. When the fuel pump module is engaged, a definite click will be heard and the (two) outside tabs on the fuel pump module will be engaged on the outside of the fuel tank retainer. The fuel pump module must be snapped in the retainer with both tabs. Pull on the fuel pump module to make sure it is fully engaged. Install sender plate to fuel tank being careful that locating keys are in keyways and O-ring seal remains in place.
Hold assembly in place and install fuel pump locking retainer ring finger-tight. Make sure that all locking tabs are under fuel pump locking retainer ring tabs.
Secure the fuel pump module unit by rotating the fuel pump locking retainer ring clockwise using Fuel Tank Sender Wrench T74P-9275-A until fuel pump locking retainer ring stops against stops.
Move fuel tank from bench to vehicle.
Install Fuel Tank in vehicle as outlined.
Install a minimum of 38 liters (10 gallons) of fuel. Check for leaks.
Turn ignition switch to RUN position for three seconds repeatedly (5 to 10 times) until Multiport Fuel Injection (MFI) Fuel Pressure Gauge T80L-9974-B shows at least 207 kPa (30 psi). Check for leaks at fittings. Start engine and recheck for leaks.
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Sunday, July 17th, 2011 AT 10:18 PM