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    Lincoln Aviator, Ford Explorer, Exp Sport, Exp Sport-Trac, Mercury Mountaineer 2000-2005

    Fuel Pump

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    Removal & Installation



    1. Before servicing the vehicle, refer to the Precautions section.
      2.  
    2. Properly relieve the fuel system pressure.
      3.  
    3. Remove or disconnect the following:

      Negative battery cable
       
      Fuel tank
       
      Fuel pressure transducer electrical connector
       
      Fuel pump assembly
       

      4.  

    To install:

    1. Install or connect the following:

      Fuel pump and align the arrow on the flange with the dimple on the fuel tank. Torque the bolts to 80 inch lbs. (9 Nm).
       
      Fuel pressure transducer electrical connector
       
      Fuel tank
       
      Negative battery cable
       

      2.  
    2. Start the vehicle, check for leaks and repair if necessary.
      3.  

    1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
      2.  
    2. Properly relieve the fuel system pressure.
      3.  
    3. Remove or disconnect the following:

      Negative battery cable
       
      Fuel tank
       
      Fuel pressure transducer electrical connector
       
      Fuel pump assembly
       

      4.  

    To install:

    1. Install or connect the following:

      Fuel pump and align the arrow on the flange with the dimple on the fuel tank. Torque the bolts to 80 inch lbs. (9 Nm).
       
      Fuel pressure transducer electrical connector
       
      Fuel tank
       
      Negative battery cable
       

      2.  
    2. Start the vehicle, check for leaks and repair if necessary.
      3.  

    1. Before servicing the vehicle, refer to the -Precautions- section.
      CAUTION
      The fuel in the system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel lines or fuel system components, the fuel pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or fire hazard.

      2.  
    2. With the vehicle in NEUTRAL, position it on a hoist.
      3.  
    3. Disconnect the battery ground cable.
      4.  
    4. Release the fuel system pressure.
      5.  
    5. Remove the rear driveshaft.
      6.  
    6. Disconnect the lower fill hose from the fuel intermediate steel by loosening worm gear clamp and pulling it off.
      7.  
    7. Insert a drain hose through the lower fill hose, past the fill tube check valve, and pump fuel out of the fuel tank.
      8.  
    8. Remove the fuel tank skid plate (if equipped).
      9.  
    9. Remove the three bolts at the outboard frame rail.
      10.  
    10. Remove the two nuts on the inboard side.
      11.  
    11. Remove the fuel tank skid plate.
      12.  
    12. Remove the fuel tank. See -Fuel Tank- section.
      13.  
    13. Clean the area around the fuel pump assembly mounting flange.
      WARNING
      The fuel pump assembly must be handled carefully to avoid damage to the float arm and the filter.

      14.  
    14. Remove the fuel pump module lock ring with the special tool and remove the fuel pump module.
      15.  
    15. Installation is the reverse of the removal procedure.

      Click image to see an enlarged view

      Fig. Fuel pump locking ring-2005 Aviator

      16.  

    1. Before servicing the vehicle, refer to the -Precautions- section.
      2.  
    2. With the vehicle in NEUTRAL, position it on a hoist.
      3.  
    3. Release the fuel system pressure.
      4.  
    4. Remove the fuel tank. See -Fuel Tank- section.
      5.  
    5. Disconnect the vapor tube fitting.
      CAUTION
      Using the special tool, remove the fuel pump locking ring.


      NOTE
      The fuel pump module must be handled carefully to avoid damage to the float arm and filter.

      6.  
    6. Remove the fuel pump module and the O-ring seal. Discard the O-ring seal.
      7.  
    7. Installation is the reverse of the removal procedure.
      8.  

    2002 Explorer Sport And Sport-Trac Built After 03/2002; All 2003 Explorer Sport And Sport-Trac; 2004-05 Explorer Sport-Trac
    1. Before servicing the vehicle, please familiarize yourself with safety procedures.
      2.  
    2. Disconnect the battery ground cable.
      3.  
    3. Release the fuel system pressure.
      4.  
    4. Drain the fuel tank.
      5.  
    5. On 4-wheel drive vehicles:
      1. Remove the fuel tank skid plate bolts.
        2.  
      2. Remove the fuel tank skid plate rear left bolt.
        3.  
      3. Remove the fuel tank skid plate rear right bolt and lower the fuel tank skid plate.
        4.  

      6.  
    6. On all vehicles:
      1. Use a suitable jack to support the fuel tank.
        2.  
      2. Remove the bolt and position the fuel tank support strap aside.
        3.  
      3. Remove the bolt and position the fuel tank support bracket aside.
        4.  
      4. Remove the bolt and push the fuel tank back until the lip clears the support bracket.
        5.  
      5. Lower the fuel tank just enough to expose the fuel and vapor hoses.
        6.  
      6. Disconnect the vapor hose.
        7.  
      7. Disconnect the fuel tank electrical supply connector near the frame rail. Lower the fuel tank.
        8.  
      8. Disconnect the fuel hoses.
        9.  
      9. Remove the fuel tank.
        10.  

      7.  
    7. Remove the fuel hoses from the fuel pump.
      8.  
    8. Clean the area around the fuel pump locking ring.
      WARNING
      The fuel pump assembly must be handled carefully to avoid damage to the float arm and the filter.

      9.  
    9. Using special tool 310-075, remove the fuel pump locking ring and remove the fuel pump assembly.
      10.  

    To install:

    1. Installation is the reverse of the removal procedure.
      2.  
    2. Use a new O-ring.
      3.  
    3. Observe the following tightening torques:

      Locking ring 55 ft. lbs.
       
      Support strap bolts to 30 ft. lbs. (40 Nm).
       
      Skid plate bolts 89 inch lbs. (10 Nm).
       

      4.  

    2002 Explorer, Mountaineer & Sport-Trac Sport Built Before 03/2002
    1. Before servicing the vehicle, please familiarize yourself with safety procedures.
      2.  
    2. Disconnect the battery ground cable.
      3.  
    3. Relieve the fuel system pressure.
      4.  
    4. Drain the fuel tank.
      5.  
    5. 4WD vehicle
      1. Remove the fuel tank skid plate bolts.
        2.  
      2. Remove the fuel tank skid plate rear left bolt.
        3.  
      3. Remove the fuel tank skid plate rear right bolt and lower the fuel tank skid plate.
        4.  

      6.  
    6. All vehicles
      1. Use a suitable jack to support the fuel tank.
        2.  
      2. Remove the vent hose.
        3.  
      3. Remove the bolt and reposition the fuel tank support strap.
        4.  
      4. Remove the support bolts and push the fuel tank back until the lip clears the support bracket.
        5.  
      5. Lower the fuel tank just enough to expose the fuel lines and the fuel tank transducer connector.
        6.  
      6. Disconnect the fuel line and the vapor line.
        7.  
      7. Disconnect the fuel tank electrical supply connector near the frame rail. Lower the fuel tank.
        8.  

      7.  
    7. Clean the area around the fuel pump assembly mounting flange.
      8.  
    8. Disconnect the electrical connector from the fuel pressure transducer.
      WARNING
      The fuel pump assembly must be handled carefully to avoid damage to the float arm and the filter.

      9.  
    9. Remove the fuel pump mounting bolts and remove the fuel pump assembly.
      10.  

    To install:

    1. Clean the fuel pump assembly mounting flange and the fuel tank mounting surface.
      2.  
    2. Position the fuel pump assembly in the fuel tank.
      3.  
    3. Align the arrow on the fuel pump flange with the dimple on the fuel tank.

      Click image to see an enlarged view

      Fig. Fuel pump flange bolt torque sequence-2002 Explorer and Mountaineer and Sport-Trac Sport Built Before 03/2002

      4.  
    4. Tighten the bolts in the sequence shown in three stages.

      Stage 1: Tighten to 30 inch lbs. (3 Nm).
       
      Stage 2: Tighten to 65 inch lbs.(7 Nm).
       
      Stage 3: Tighten to 93 inch lbs. (10 Nm).
       

      5.  
    5. Connect the electrical connector to the fuel pressure transducer.
      6.  
    6. To install the tank, reverse the removal procedure.
      7.  
    7. Observe the following tightening torques:

      Fuel tank support and strap bolts to 30 ft. lbs. (40 Nm).
       
      Skid plate bolts to 89 inch lbs. (10 Nm).
       

      8.  

    2002-03 Explorer And Mountaineer; 2004 Explorer And Mountaineer With 4.0L SOHC Early Build; 2003-05 Aviator


    Click image to see an enlarged view

    Fig. Fuel tank, pump and related parts-2002-03 Explorer and Mountaineer; 2004 Explorer and Mountaineer with 4.0L SOHC Early Build



    Click image to see an enlarged view

    Fig. Fuel pump locking ring-2002-03 Explorer and Mountaineer and 2004 Explorer and Mountaineer with 4.0L SOHC Early Build; 2003-05 Aviator

    1. Before servicing the vehicle, please familiarize yourself with safety procedures.
      CAUTION
      The fuel in the system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel lines or fuel system components, the fuel pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or fire hazard.

      2.  
    2. With the vehicle in NEUTRAL, position it on a hoist.
      3.  
    3. Disconnect the battery ground cable.
      4.  
    4. Release the fuel system pressure.
      5.  
    5. Remove the rear driveshaft.
      6.  
    6. Disconnect the lower fill hose from the fuel intermediate steel by loosening worm gear clamp and pulling it off.
      7.  
    7. Insert a drain hose through the lower fill hose, past the fill tube check valve, and pump fuel out of the fuel tank.
      8.  
    8. Remove the fuel tank skid plate (if equipped).
      9.  
    9. Remove the three bolts at the outboard frame rail.
      10.  
    10. Remove the two nuts on the inboard side.
      11.  
    11. Remove the fuel tank skid plate.
      12.  
    12. If equipped, remove the transfer case skid plate by removing four bolts from the outer frame rail (two per side).
      13.  
    13. Disconnect the transmission-mounted fuel vapor line from the plastic fitting on the forward canister. This is a squeeze release connector.
      14.  
    14. Remove the fuel filter heat shield from the nose of the fuel tank.
      15.  
    15. Remove the two nuts.
      16.  
    16. Remove the heat shield.
      17.  
    17. Disconnect the transmission-mounted fuel supply line from the fuel filter. There is a redundant latch that will unhook first. Then a quick-connect fitting that will require a quick disconnect tool to remove.
      18.  
    18. Push the fuel line out of the retaining clip at the top rear of the fuel tank.
      19.  
    19. Disconnect the vapor line on the filler pipe from the tank (quick connector is on the frame rail side of tank on the top in the rear and can be accessed through the passenger rear tire opening or from the ground with the vehicle on a hoist.) Push the button on the side to release.
      20.  
    20. Disconnect the vapor line from the canister vent valve, which is located on the inside frame rail just rearward of the fuel tank.
      21.  
    21. Use a suitable jack to support the fuel tank.
      22.  
    22. Remove the fuel tank strap nut.
      23.  
    23. Remove the fuel tank strap bolt and lower tank.
      24.  
    24. Lower the tank slightly and disconnect the electrical connector from the pump sender to the frame loom.
      25.  
    25. Remove the fuel tank.
      26.  
    26. Clean the area around the fuel pump assembly mounting flange.
      WARNING
      The fuel pump assembly must be handled carefully to avoid damage to the float arm and the filter.

      27.  
    27. Remove the fuel pump module lock ring with the special tool and remove the fuel pump module.
      28.  

    To install:

    1. Installation is the reverse of the removal procedure.
      2.  

    4.0L SOHC Late Build


    Click image to see an enlarged view

    Fig. Fuel tank and related parts-2004 Explorer and Mountaineer 4.0L SOHC Late Build and all 2004-05 Explorer and Mountaineer



    Click image to see an enlarged view

    Fig. Fuel pump module-2004 Explorer and Mountaineer 4.0L SOHC Late Build and all 2004-05 Explorer and Mountaineer

    1. Before servicing the vehicle, please familiarize yourself with safety procedures.
      CAUTION
      Fuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.

      2.  
    2. With the vehicle in NEUTRAL, position it on a hoist.
      CAUTION
      Release the fuel system pressure.

      3.  
    3. Disconnect the battery negative cable.
      4.  
    4. Remove the driveshaft.
      CAUTION
      Drain the fuel tank.


      CAUTION
      If equipped, remove the 4 bolts and the transfer case skid plate.

      5.  
    5. Disconnect the filler pipe vapor tube fitting.
      6.  
    6. Disconnect the fuel vapor vent valve-to-fuel pressure sensor and tube assembly hose.
      7.  
    7. Remove the bolts and the fuel filter heat shield.
      8.  
    8. Remove the nuts and the fuel filter shield.
      9.  
    9. Disconnect the fuel filter spring lock coupling.
      10.  
    10. Disconnect the fuel pressure sensor and tube assembly-to-vapor tube fitting.
      CAUTION
      If equipped, remove the 3 bolts, 2 nuts and the fuel tank skid plate.


      CAUTION
      Using a suitable jack, support the fuel tank.

      11.  
    11. Remove the bolt and the fuel tank rear support strap.
      12.  
    12. Remove the nut and the fuel tank front support strap.
      CAUTION
      Lower the fuel tank far enough to access the fuel pump electrical connector and disconnect the connector.

      13.  
    13. Remove the fuel tank from the vehicle.
      14.  
    14. Disconnect the vapor tube fitting.
      CAUTION
      Using the special tool, remove the fuel pump locking ring.


      NOTE
      The fuel pump module must be handled carefully to avoid damage to the float arm and filter.

      15.  
    15. Remove the fuel pump module and the O-ring seal. Discard the O-ring seal.
      16.  

    To install:


    NOTE
    The fuel pump module must be handled carefully to avoid damage to the float arm and filter.


    NOTE
    Lubricate the O-ring seal with clean engine oil.


    CAUTION
    Install a new O-ring seal and the fuel pump module.


    NOTE
    The fuel pump module locking ring is a cam-type lock. Turn the locking ring until it stops and is locked in place.


    CAUTION
    Using the special tool, install the fuel pump module locking ring.


    CAUTION
    Connect the vapor tube fitting.


    CAUTION
    To install the fuel tank, reverse the removal procedure. Observe the following torques:



    Fuel tank front support strap: 41 ft lbs. (55 Nm)
     
    Fuel tank skid plate: 30 ft. lbs. (40 Nm).
     
    Fuel filter shield: 44 inch lbs. (5 Nm).
     
    Fuel filter heat shield: 15 ft. lbs. (20 Nm).
     
    Transfer case skid plate: 30 ft. lbs. (40 Nm).
     

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