Ford Fusion: Fuel Tank and Lines - 1.5L EcoBoost (118kW/160PS) – I4 / Fuel Pump and Sender Unit. Removal and Installation

Special Tool(s) / General Equipment

310-123 Locking Ring, Fuel Tank TKIT-2004J-F TKIT-2005U-LM

Removal

NOTE: Removal steps in this procedure may contain installation details.

1.   WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

   Refer to: Gasoline and Gasoline-Ethanol Fuel Systems Health and Safety Precautions (100-00 General Information, Description and Operation).
   

1. Remove the Fuel Tank.
   Refer to: Fuel Tank (310-01A Fuel Tank and Lines - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
   

1. Release the quick release coupling.
   Refer to: Quick Release Coupling (310-00A Fuel System - General Information - 1.5L EcoBoost (118kW/160PS) – I4, General Procedures).
   

1. NOTICE: The Fuel Pump and Sender Unit must be handled carefully to avoid damage to the float arm.

   NOTE: To avoid introducing contamination into the fuel tank use compressed air to clean the Fuel Pump and Sender Unit connections, couplings, flange surfaces and the immediate surrounding area of any dirt or foreign material.

   NOTE: Place absorbent toweling in the immediate surrounding area in case of fuel spillage.

   NOTE: Some residual fuel may remain in the Fuel Pump and Sender Unit. Carefully drain into a suitable container.

   Carefully lift the Fuel Pump and Sender Unit from the fuel tank allowing access and disconnect internal transfer tube quick connect coupling (If Equipped). Remove the Fuel Pump and Sender Unit.
   Refer to: Quick Release Coupling (310-00A Fuel System - General Information - 1.5L EcoBoost (118kW/160PS) – I4, General Procedures).
   Use Special Service Tool: 310-123  Locking Ring, Fuel Tank.

1. NOTE: Inspect the mating surfaces of the Fuel Pump and Sender Unit flange and fuel tank O-ring seal contact surfaces. Wipe clean with a lint free towel. Install a new Fuel Pump and Sender Unit or fuel tank if the Oring seal contact area is bent, scratched or corroded.

   NOTE: Remove and discard the Fuel Pump and Sender Unit O-ring seal.

Installation

1. NOTE: Make sure to install a new Fuel Pump and Sender Unit O-ring seal.

   NOTE: Make sure the alignment tabs on the Fuel Pump and Sender Unit and the fuel tank meet prior to tightening the Fuel Pump and Sender Unit lock ring.

   To install, reverse the removal procedure.