This procedure replaces the fuel pump assembly in a 2011-2014 Ford F-150 with 3.5L EcoBoost engine by accessing the fuel tank through the bed-mounted access cover.

Warnings

Tools required

Parts

• Fuel pump module assembly × 1 — Motorcraft PFS-500 or equivalent
• Fuel pump lock ring seal/gasket × 1 — Use OEM specification
• Fuel line O-rings × 2 — Use OEM specification

Preparation

1. Park vehicle on level ground outdoors or in well-ventilated area away from ignition sources
2. Ensure fuel tank is less than 1/2 full to minimize spillage (if necessary, siphon or drive to reduce fuel level)
3. Place Class B fire extinguisher within immediate reach of work area
4. Disconnect negative battery cable and wait 5 minutes to allow fuel pump to fully depressurize
5. Relieve fuel system pressure: Remove fuel pump relay (F33 in battery junction box), reconnect battery, attempt to start engine until it stalls, then crank for 5 seconds to ensure depressurization
6. Disconnect negative battery cable again before proceeding
7. Gather all required tools, parts, shop towels, and drain pan before beginning

Procedure

1. 1

   Access fuel pump module
   Fold rear seats forward to access the fuel pump access cover located under the rear seat area toward the driver's side. The access cover is a rectangular metal or plastic panel secured with screws. Some models may require removal of carpet or sound deadening material.
2. 2

   Remove access cover
   Remove the access cover screws using appropriate Torx or Phillips driver. Carefully lift the access cover to expose the fuel pump module lock ring and fuel lines. Verify you can see the fuel pump module top with electrical connector and fuel lines attached.
3. 3

   Disconnect electrical connector
   Disconnect the fuel pump module electrical connector by pressing the locking tab and pulling straight up. Ensure connector is completely separated and positioned away from work area to prevent contamination.
   ⚠Do not pull on wires. Press the connector lock tab firmly while pulling on the connector body only.
4. 4

   Disconnect fuel supply and return lines
   Using fuel line disconnect tools, disconnect the fuel supply line and return line (if equipped) from the fuel pump module. Place shop towels around connections to catch residual fuel. Push the disconnect tool onto the line, then pull the line straight out. Place disconnected lines into drain pan to catch any dripping fuel.
   ⚠️Expect residual fuel spray. Wear safety glasses and have towels ready. Keep drain pan positioned to catch all fuel.
5. 5

   Remove fuel pump lock ring
   Install the fuel pump lock ring tool onto the lock ring tabs. Carefully tap the tool counterclockwise using a hammer or turn with a breaker bar (depending on tool type) to loosen the lock ring. The lock ring is under spring tension and may release suddenly. Once loosened, unscrew the lock ring completely by hand and remove it.
   ⚠Lock ring is under spring tension from the fuel pump module. Control the lock ring as it loosens to prevent it from suddenly releasing.
6. 6

   Remove fuel pump module seal
   Remove the old fuel pump lock ring seal/gasket from the top of the fuel tank opening. Inspect the sealing surface on the tank for debris, corrosion, or damage. Clean the sealing surface thoroughly with shop towels. Any debris or damage will cause fuel leaks.
   ⚠Sealing surface must be completely clean and undamaged for proper seal. Inspect carefully for any scratches or corrosion that could prevent sealing.
7. 7

   Remove old fuel pump module
   Carefully lift the fuel pump module assembly from the fuel tank. Tilt the module to clear the fuel level sensor float arm and fuel strainer from the tank opening. Be aware that the module will be dripping with fuel. Keep the drain pan positioned to catch fuel. Place the old module in the drain pan.
   ⚠️Module will be saturated with gasoline. Move slowly to prevent splashing. Keep away from ignition sources.
8. 8

   Inspect fuel tank interior
   Using a flashlight, inspect the interior of the fuel tank through the access opening for debris, contamination, rust, or damage. If significant debris is present, the tank may require additional cleaning or service before installing the new pump.
9. 9

   Prepare new fuel pump module
   Remove the new fuel pump module from packaging. Install new O-rings on fuel line connections if provided with pump assembly. Verify the new lock ring seal/gasket is ready for installation. Check that the fuel level sensor float arm moves freely and the strainer is properly attached.
10. 10

    Install new fuel pump module
    Position the new fuel pump lock ring seal/gasket onto the fuel tank opening, ensuring it seats properly in the groove. Carefully lower the new fuel pump module into the tank, tilting as needed to clear the float arm and strainer. Align the module so the orientation marks (arrows or tabs) match the tank markings. The module must be fully seated against the seal.
    ⚠Proper alignment is critical. The module has a specific orientation to ensure proper fuel pickup and level sensing. Verify alignment marks before proceeding.
11. 11

    Install and torque lock ring
    Thread the fuel pump lock ring onto the tank opening by hand, turning clockwise until hand-tight. Install the lock ring tool and torque the lock ring to specification clockwise. Verify the lock ring is fully seated and the seal is not pinched or displaced.
    ⚠CRITICAL TORQUE: Lock ring must be torqued to exactly 75 Nm (55 lb-ft). Under-torquing will cause fuel leaks; over-torquing can damage the tank threads or module.
12. 12

    Connect fuel lines
    Connect the fuel supply line and return line (if equipped) to the fuel pump module. Push each line firmly onto the module fitting until you hear and feel a distinct click. Gently pull on each line to verify it is securely locked in place.
    ⚠Lines must click and lock securely. An improperly connected fuel line will cause dangerous fuel leaks under pressure.
13. 13

    Connect electrical connector
    Connect the fuel pump module electrical connector by aligning and pushing firmly until the locking tab clicks into place. Verify the connection is secure by gently pulling on the connector.
14. 14

    Reinstall access cover
    Position the access cover over the fuel pump module area. Install and tighten the access cover screws to specification in a cross pattern to ensure even sealing.

Reassembly

1. Reinstall fuel pump relay (F33) in battery junction box
2. Reconnect negative battery cable
3. Return rear seats to normal position
4. Replace any carpet or sound deadening material that was moved

Verification

• Turn ignition key to ON position (do not start) for 5 seconds to prime fuel system, then OFF. Repeat 3 times to build fuel pressure
• Inspect access cover area and all fuel line connections for any signs of fuel leakage
• Start engine and verify it runs normally without stumbling or hesitation
• With engine running, inspect fuel pump area and all connections again for leaks using a flashlight
• Allow engine to idle for 5 minutes while monitoring for any fuel odors or leaks
• Test drive vehicle to verify normal fuel delivery and performance under load
• After test drive, perform final inspection of all fuel connections and access cover area for any seepage or leaks
• If any fuel smell or leakage is detected, immediately shut off engine and investigate cause before operating vehicle

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