Fuel Tank Draining

	Fuel Storage Tanker 164-R3202 or equivalent
	Fuel Tank Sender Unit Wrench 310-123

All 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, MOUNTING AND CABLES .
3. NOTE: The supplemental refueling adapter is located in the luggage compartment.

   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.

   Fig 1: Installing Supplemental Refueling Adapter And Length

   Courtesy of FORD MOTOR CO.
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.

   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 UNI-BODY, SUBFRAME AND MOUNTING SYSTEM .
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.
7. Remove the rear seat cushion. For additional information, refer to SEATING .
8. Remove the FP  module and fuel level sensor access covers and position aside.
   Fig 2: Identifying FP Module And Fuel Level Sensor

   Courtesy 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.

   Disconnect the FP  module electrical connector.

   Fig 3: Locating FP Module Electrical Connector

   Courtesy of FORD MOTOR CO.

   5.8L (4V) vehicles 

10. 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.

    Fig 4: Locating FP Module Electrical Connector

    Courtesy of FORD MOTOR CO.

    All vehicles 

11. NOTE: Place absorbent pads in the general work area in case of fuel spillage.

    Disconnect the rear fuel tube-to-FP  module quick connect coupling. For additional information, refer to Quick Connect Coupling  .

    Fig 5: Locating Rear Fuel Tube-To-FP Module Quick Connect Coupling

    Courtesy of FORD MOTOR CO.
12. 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.

    Install the Fuel Tank Sender Unit Socket and remove the FP  module lock ring.

    Fig 6: Installing Fuel Tank Sender Unit Socket

    Courtesy of FORD MOTOR CO.
13. NOTE: The Fuel Pump (FP) module must be handled carefully to avoid damage to the float arm.

    Position the FP  module aside. Using the Fuel Storage Tanker, completely drain the remaining fuel from the LH saddle of the fuel tank.

    Fig 7: Locating Fuel Pump Module

    Courtesy of FORD MOTOR CO.
14. 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.

    Remove and discard the FP  module O-ring seal.

15. NOTE: Clean the fuel level sensor connections, flange surfaces and the immediate surrounding area of any dirt or foreign material.

    Disconnect the fuel level sensor electrical connector.

    Fig 8: Locating Fuel Level Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
16. 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.

    Install the Fuel Tank Sender Unit Socket and remove the fuel level sensor lock ring.

    Fig 9: Removing Fuel Level Sensor Lock Ring

    Courtesy of FORD MOTOR CO.
17. NOTE: The fuel level sensor must be handled carefully to avoid damage to the float arm.

    Position the fuel level sensor aside. Using the Fuel Storage Tanker, completely drain the RH saddle of the fuel tank.

    Fig 10: Locating Fuel Level Sensor Float Arm

    Courtesy of FORD MOTOR CO.
18. 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.

    Remove and discard the fuel level sensor O-ring seal.