Zephyr 2006, Fusion & Milan 2006-2007, MKZ 2007

Relieving Fuel System Pressure


Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

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 components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury.

Fuel in the fuel system remains under high pressure, even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, which may cause personal injury or a fire hazard.

The fuel pump relay is located in the battery junction box (BJB), relay number 54.

  1. Remove the fuel pump relay.

    Click image to see an enlarged view

    Fig. Fuel pump relay location

  3. Start the engine and allow it to idle until it stalls.
  5. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel injection supply manifold pressure has been released.
  7. Turn the ignition switch to the OFF position.
  9. When fuel system service is complete, install the fuel pump relay.
    It may take more than one key cycle to pressurize the fuel system.

  11. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine.
  13. Start the vehicle and check the fuel system for leaks