This procedure replaces the fuel pump module assembly in the fuel tank, requiring fuel tank lowering and fuel system depressurization.

Warnings

Tools required

Parts

• Fuel pump module assembly × 1 — Motorcraft PFS-494 or equivalent
• Fuel pump lock ring O-ring seal × 1 — Use OEM specification
• Fuel line O-rings × 3 — Use OEM specification
• Fuel tank strap mounting bolts × 4 — Use OEM specification if corroded

Preparation

1. Park vehicle on level, stable surface and engage parking brake
2. Ensure adequate ventilation in work area and remove all ignition sources
3. Place fire extinguisher within immediate reach
4. Disconnect negative battery terminal and isolate cable away from battery post
5. Allow engine to cool completely if recently operated
6. Relieve fuel system pressure: Remove fuel pump fuse (F-13, 20A in engine compartment fuse box), start engine and let it run until it stalls from fuel starvation, then attempt to start 2-3 more times to ensure complete depressurization
7. Raise vehicle and support securely on jack stands at frame rails. Vehicle must be level
8. If fuel tank is more than 1/4 full, siphon fuel into approved fuel storage containers using fuel-safe hand pump

Procedure

1. 1

   Access fuel tank from underneath vehicle
   Working from beneath the vehicle, identify the fuel tank location between the frame rails ahead of the rear axle. Locate the two fuel tank support straps. Clean area around fuel tank connections to prevent debris from entering fuel system during disassembly.
2. 2

   Disconnect fuel filler neck and vent lines
   Locate the fuel filler neck hose connecting to the tank at the driver side rear. Loosen the hose clamp securing the filler neck to the tank using a flathead screwdriver or nut driver. Slide the clamp back on the hose and carefully twist and pull the filler neck away from the tank. Disconnect the EVAP vent line from the tank using spring lock coupling tool - push the tool over the line and push inward to release, then pull line free.
   ⚠Fuel may spill from filler neck. Have drain pan ready and allow fuel to drain completely before proceeding.
3. 3

   Disconnect electrical connector
   Locate the fuel pump module electrical connector on top of the tank. Press the tab release and carefully disconnect the connector. Ensure connector is positioned away from work area and will not be damaged when lowering tank.
4. 4

   Disconnect fuel supply and return lines
   Identify the fuel supply line (larger diameter) and return line connected to the fuel pump module on top of the tank. These use spring lock couplings. For each line: select correct size spring lock tool, slide tool over the line to the coupling, push inward firmly to compress the internal garter spring, then pull the line straight out. Inspect O-rings on lines for damage.
   ⚠Residual fuel pressure may remain despite depressurization. Have rags ready to catch fuel spillage. Expect approximately 1/4 cup of fuel to drain from each line.
5. 5

   Support fuel tank with transmission jack
   Position transmission jack or floor jack with wooden block under the center of the fuel tank. Raise jack until it makes firm contact with tank and supports the weight, but do not lift tank. Ensure tank is stable and balanced on jack before proceeding.
   ⚠️Fuel tank can shift unexpectedly when straps are loosened. Ensure jack is centered and stable. Have a helper guide the tank if working alone is unsafe.
6. 6

   Remove fuel tank support straps
   Locate the two fuel tank support strap bolts at the rear of each strap where they attach to the frame. Using a socket wrench, remove the rear mounting bolt from each strap (bolts may be 15mm or 18mm depending on production date). The straps will pivot down from the front mounting point. Carefully lower the jack 4-6 inches to tilt the tank enough to access the top, ensuring all lines and connections are clear.
   ⚠Support straps are under tension and may release suddenly. Control strap movement as bolts are removed.
   Torque spec

   Mounting Bolts34 Nm (25 lb-ft)
7. 7

   Clean fuel pump module access area
   With the tank lowered, clean the area around the fuel pump module lock ring on top of the tank using shop rags. Remove all dirt, debris, and corrosion to prevent contamination from entering the fuel tank when the module is removed. The lock ring is a large plastic ring approximately 8 inches in diameter with notches around the perimeter.
8. 8

   Remove fuel pump lock ring
   Install the fuel pump lock ring tool onto the lock ring, engaging the tool tabs into the lock ring notches. Using a breaker bar or long-handled ratchet in the tool, rotate the lock ring counterclockwise to loosen. Initial breakaway will require significant force (85 Nm was used during installation). Once loosened, remove the tool and unthread the lock ring by hand, lifting it away from the tank.
   ⚠Lock ring may be tight. Do not use excessive force or strike with hammer as this can damage the plastic ring or create sparks.
   Torque spec

   Fuel Pump Lock Ring85 Nm (63 lb-ft)
9. 9

   Remove fuel pump module assembly
   Carefully lift the fuel pump module assembly straight up and out of the fuel tank opening. The module includes the fuel pump, fuel level sender, and associated float arm. Tilt the module slightly as needed to maneuver the float arm and fuel level sender out of the opening without damage. Allow fuel to drain from module into the tank. Note the orientation and position of the module for installation reference.
   ⚠Module assembly is delicate. The fuel level sender float arm and wiring can be damaged if forced. Work carefully and slowly.
10. 10

    Remove and inspect old seal
    Remove the large O-ring seal from the groove in the fuel tank opening. Inspect the groove for debris, corrosion, or damage. Clean the sealing surface thoroughly with a clean, lint-free rag. Do not use solvents that may contaminate the fuel system. Verify the new seal matches the old seal in diameter and cross-section.
11. 11

    Install new fuel pump module
    Install the new O-ring seal into the groove in the fuel tank opening, ensuring it is fully seated with no twists or kinks. Lubricate the O-ring lightly with clean engine oil or fresh gasoline. Carefully lower the new fuel pump module into the tank opening, aligning the module orientation marks with the tank reference marks (typically an arrow on the module should point toward the front of the vehicle). Guide the float arm and sender carefully through the opening.
    ℹ️Correct module orientation is critical for accurate fuel level reading. Verify alignment before installing lock ring.
12. 12

    Install and torque fuel pump lock ring
    Thread the lock ring onto the tank opening by hand clockwise until it contacts the module flange. Install the lock ring tool and torque the lock ring to 85 Nm (63 lb-ft) in a clockwise direction. Verify the module is fully seated and the O-ring seal is not pinched or displaced.
    Torque spec

    Fuel Pump Lock Ring85 Nm (63 lb-ft)
13. 13

    Raise and secure fuel tank
    Carefully raise the fuel tank using the transmission jack until the tank is back in its original mounted position against the floor pan. Align the tank support straps to their mounting points. Install the strap mounting bolts and torque to 34 Nm (25 lb-ft). Remove the transmission jack.
    ⚠Ensure no fuel lines, electrical wiring, or vent hoses are pinched between tank and vehicle body as tank is raised.
    Torque spec

    Mounting Bolts34 Nm (25 lb-ft)
14. 14

    Reconnect fuel lines with new O-rings
    Install new O-rings on the fuel supply and return line ends. Lubricate the O-rings with clean engine oil. Push each fuel line straight onto the fuel pump module fittings until a distinct click is heard indicating the spring lock coupling has engaged. Pull back on each line to verify secure connection.
    ℹ️Do not reuse old O-rings. Damaged O-rings will cause fuel leaks under pressure.
15. 15

    Reconnect electrical and filler connections
    Reconnect the fuel pump module electrical connector, ensuring it clicks fully into place. Reconnect the EVAP vent line using spring lock coupling until it clicks. Slide the fuel filler neck onto the tank inlet and position the hose clamp over the connection. Tighten the clamp screw to 3.0 Nm (2.0 lb-ft).
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)

Reassembly

1. Lower vehicle from jack stands
2. Reconnect negative battery terminal
3. Reinstall fuel pump fuse (F-13) in engine compartment fuse box
4. If fuel was siphoned, refill tank with at least 5 gallons of fresh gasoline

Verification

• Turn ignition key to ON position (do not start) for 5 seconds, then OFF. Repeat 3-4 times to prime fuel system and pressurize fuel lines
• Inspect all fuel line connections, lock ring seal, and filler neck for fuel leaks while system is pressurized
• Start engine and verify it runs smoothly without stumbling or fuel starvation symptoms
• With engine running, inspect underneath vehicle for any fuel leaks at tank connections and fuel lines
• Verify fuel gauge reads correctly and corresponds to actual fuel level in tank
• Test drive vehicle and monitor for proper fuel delivery under acceleration and load
• After test drive, perform final inspection underneath vehicle for any signs of fuel leakage

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