Ford Freestar, Monterey 2004-2006

Fuel Pump

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Removal & Installation




NOTE
To gain access to the fuel pump, it is necessary to remove the fuel tank. The fuel tank is equipped with a composite protective shield mounted with the support straps and retainers on the right side of the tank. Make sure the shield is correctly installed when installing the tank.

  1. Disconnect the negative battery cable.
  2.  
  3. Depressurize the fuel system and drain the fuel into a suitable container.
  4.  
  5. Remove the fuel filler pipe.
    CAUTION
    Some fuel may remain in the filler pipe.

  6.  
  7. Support the fuel tank.
  8.  
  9. Disconnect the electrical connectors and fuel line fittings.
  10.  
  11. Disconnect the retaining straps and lower the tank.
  12.  
  13. Remove any dirt that has accumulated around the fuel pump module attaching flange to prevent it from entering the tank during service.

    Click image to see an enlarged view

    Fig. In-tank electric fuel pump and related components-Freestar and Monterey 2004-05 models



    Click image to see an enlarged view

    Fig. In-tank electric fuel pump and related components-Freestar and Monterey 2006 models

  14.  
  15. Turn the fuel pump module locking ring counterclockwise using a locking ring removal tool, and remove the locking ring.
  16.  
  17. Remove the fuel pump module.
  18.  
  19. Remove the seal gasket and discard it.
  20.  

To install:

  1. Put a light coating of grease on a new seal ring to hold it in place during assembly. Install it in the fuel tank ring groove.
  2.  
  3. Insert the fuel pump module into the fuel tank, then secure it in place with the locking ring. Tighten the ring to 60 ft. lbs. (81 Nm).
  4.  
  5. Install the tank in the vehicle.
  6.  
  7. Install a minimum of 10 gallons (38L) of fuel and check for leaks.
  8.  
  9. Check for fuel leaks at the fittings.
  10.  
  11. Start the engine and check for fuel leaks.
  12.  

 
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