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Fuel Tank Draining

SPECIAL TOOLS

G06064441
 Fuel Storage Tanker
164-R3202 or equivalent
G06396137
 Socket, Fuel Tank Sender Unit
310-D006 (D90P-9275-A) or equivalent
G06075093
 Fuel Tank Sender Unit Wrench
310-123
MATERIAL SPECIFICATIONS

Item Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada)
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)		 WSS-M2C945-A
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: 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.
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.

3.7L, 5.0L (4V) and 5.4L (4V) vehicles 

  1. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM PRESSURE RELEASE .
  2. Disconnect the battery ground cable. For additional information, refer to BATTERY, BATTERY MOUNTING & BATTERY CABLES .
    3. NOTE: The supplemental refueling adapter is located in the luggage compartment.
    Fig 1: Locating Drain Tube And Supplemental Refueling Adapter
    G06261576Courtesy of FORD MOTOR CO.
  3. Install the supplemental refueling adapter and a length of semi-rigid fuel drain tube into the Easy Fuel™ (capless) fuel tank filler pipe until the tube enters the fuel tank.
    4. NOTE: This step is to remove approximately one-eighth tank of the fuel from a completely full fuel tank and the majority of any residual fuel in the fuel tank filler pipe, lowering the fuel level below the Fuel Pump (FP) module mounting flange.
  4. Attach the Fuel Storage Tanker to the fuel drain tube and remove approximately one-eighth (approximately 2 gallons) of fuel from the tank.
  5. If equipped, remove the rear support braces. For additional information, refer BODY SYSTEM - UNI-BODY, SUBFRAME & MOUNTING SYSTEM .

    3.7L and 5.0L (4V) vehicles 

  6. Lower the fuel tank.
    1. Lift the vehicle. For additional information, refer to JACKING & LIFTING .
    2. Support the fuel tank.
    3. Remove the fuel tank strap bolts.
      • Tighten to 52 Nm (38 lb-ft).
    4. By hand, reinstall the fuel tank strap bolts three full turns.
    5. Remove the fuel tank support.
    6. Lower the vehicle.

    3.7L, 5.0L (4V) and 5.4L (4V) vehicles 

  7. Remove the rear seat cushion. For additional information, refer to SEAT SYSTEM - SEATS .
  8. Remove the FP module and fuel level sensor access covers and position aside.
    Fig 2: Locating FP Module And Fuel Level Sensor Access Covers
    G06396139Courtesy of FORD MOTOR CO.

    3.7L and 5.0L (4V) vehicles 

    9. NOTE: Clean the FP module connections, couplings, flange surfaces and the immediate surrounding area of any dirt or foreign material.
    Fig 3: Locating FP Module Electrical Connector (3.7L And 5.0L (4V) Vehicles)
    G07489119Courtesy of FORD MOTOR CO.
  9. Disconnect the FP module electrical connector.

    5.4L (4V) vehicles 

    10. NOTE: Clean the FP module connections, couplings, flange surfaces and the immediate surrounding area of any dirt or foreign material.
    Fig 4: Locating FP Module Electrical Connector (5.4L (4V) Vehicles)
    G06396140Courtesy of FORD MOTOR CO.
  10. Disconnect the FP module electrical connector.

    3.7L and 5.0L (4V) vehicles 

    11. NOTE: Place absorbent pads in the general work area in case of fuel spillage.
    Fig 5: Locating Rear Fuel Tube-To-FP Module Quick Connect Coupling (3.7L And 5.0L (4V) Vehicles)
    G07489121Courtesy of FORD MOTOR CO.
  11. Disconnect the rear fuel tube-to-FP module quick connect coupling. For additional information, refer to appropriate procedures in this service information .

    5.4L (4V) vehicles 

    12. NOTE: Place absorbent pads in the general work area in case of fuel spillage.
    Fig 6: Locating Rear Fuel Tube-To-FP Module Quick Connect Coupling (5.4L (4V) Vehicles)
    G06396141Courtesy of FORD MOTOR CO.
  12. Disconnect the rear fuel tube-to-FP module quick connect coupling. For additional information, refer to appropriate procedures in this service information .

    3.7L and 5.0L (4V) vehicles 

    13. NOTE: Carefully install the Fuel Tank Sender Unit Socket to avoid damage to the Fuel Pump (FP) module when removing the lock ring.
    NOTE: When installing the FP module, install a new O-ring seal.
    Fig 7: Installing Fuel Tank Sender Unit Socket
    G07489123Courtesy of FORD MOTOR CO.
  13. Install the Fuel Tank Sender Unit Socket and remove the FP module lock ring.

    5.4L (4V) vehicles 

    14. NOTE: Carefully install the Fuel Tank Sender Unit Socket to avoid damage to the Fuel Pump (FP) module when removing the lock ring.
    NOTE: When installing the FP module, install a new O-ring seal.
    Fig 8: Removing FP Module Retaining Lock Ring
    G06396142Courtesy of FORD MOTOR CO.
  14. Install the Fuel Tank Sender Unit Socket and remove the FP module lock ring.

    3.7L, 5.0L (4V) and 5.4L (4V) vehicles 

    15. NOTE: The Fuel Pump (FP) module must be handled carefully to avoid damage to the float arm.
    Fig 9: Locating LH Saddle Of Fuel Tank
    G06396143Courtesy of FORD MOTOR CO.
  15. Position the FP module aside. Using the Fuel Storage Tanker, completely drain the remaining fuel from the LH saddle of the fuel tank.
    16. 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.
  16. Remove and discard the FP module O-ring seal.
    17. NOTE: Clean the fuel level sensor connections, flange surfaces and the immediate surrounding area of any dirt or foreign material.
    Fig 10: Locating Fuel Level Sensor Electrical Connector
    G06396144Courtesy of FORD MOTOR CO.
  17. Disconnect the fuel level sensor electrical connector.

    3.7L and 5.0L (4V) vehicles 

    18. NOTE: Carefully install the Fuel Tank Sender Unit Socket to avoid damage to the fuel level sensor when removing the lock ring.
    NOTE: When installing the fuel level sensor, install a new O-ring seal.
    Fig 11: Removing Fuel Level Sensor Lock Ring
    G07489127Courtesy of FORD MOTOR CO.
  18. Install the Fuel Tank Sender Unit Socket and remove the fuel level sensor lock ring.

    5.4L (4V) vehicles 

    19. NOTE: Carefully install the Fuel Tank Sender Unit Socket to avoid damage to the fuel level sensor when removing the lock ring.
    NOTE: When installing the fuel level sensor, install a new O-ring seal.
    Fig 12: Removing Fuel Level Sensor Retaining Lock Ring
    G06396145Courtesy of FORD MOTOR CO.
  19. Install the Fuel Tank Sender Unit Socket and remove the fuel level sensor lock ring.

    3.7L, 5.0L (4V) and 5.4L (4V) vehicles 

    20. NOTE: The fuel level sensor must be handled carefully to avoid damage to the float arm.
    Fig 13: Locating RH Saddle Of Fuel Tank
    G06396146Courtesy of FORD MOTOR CO.
  20. Position the fuel level sensor aside. Using the Fuel Storage Tanker, completely drain the RH saddle of the fuel tank.
    21. NOTE: Inspect the surfaces of the fuel level sensor 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 fuel level sensor 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.
  21. Remove and discard the fuel level sensor O-ring seal.
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