Remove the two bolts and the fuel tank front and rear support straps. Note the routing of the fuel vent hose at this time. NOTE: The location of the fuel vent hose is critical to fuel system operation.Position a suitable jack under the fuel tank. Damage to the fuel pump assembly can occur. CAUTION: Do not support the fuel tank directly beneath the fuel pump mounting area.Disconnect the vapor tube from the evaporative emissions ( EVAP) system dust separator.Disconnect the vapor tube and the fuel filter outlet tube forward of the fuel tank.Disconnect the two vapor tubes at the rear of the fuel tank.To install, tighten to 20 Nm (15 lb-ft).If equipped, remove the four nuts and the fuel tank skid plate.With the vehicle in NEUTRAL, position it on a hoist.When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube.Always install blanking plugs to any open orifices or tubes. It is therefore essential that absolute cleanliness is observed when working with these components. Fuel injection equipment is manufactured to very precise tolerances and fine clearances.Before servicing or disconnecting any of the fuel tubes or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard. Fuel in the fuel system remains under high pressure even when the engine is not running.

Failure to follow these instructions may result in personal injury.

Highly flammable mixtures are always present and can be ignited. Do not smoke, carry lighted tobacco or open flame of any type when working on or near any fuel-related component.

To remove the pump from the tank you will need a special lock ring tool OTC part #310-123 which you can find online for around $260.00Įxploded View Removal and Installation WARNING:

2005 expedition fuel pump install