Ford Explorer: Fuel Tank and Lines - 2.3L EcoBoost (201kW/273PS) / Removal and Installation - Fuel Pump and Sender Unit

Special Tool(s) / General Equipment

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

Removal

  WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures may be present and may be ignited. Failure to follow these instructions may result in serious personal injury.

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

1. With the vehicle in NEUTRAL, position it on a hoist.
   Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
   

1. Remove the Fuel Tank.
   Refer to: Fuel Tank (310-01A Fuel Tank and Lines - 2.3L EcoBoost (201kW/273PS), Removal and Installation).
   

1. Remove the bolt and shield.
   Torque: 53 lb.in (6 Nm)

1. NOTE: To avoid introducing contamination into the fuel tank use compressed air to clean the fuel pump and sender unit flange surfaces and the immediate surrounding area of any dirt or foreign material.

   Remove the quick connectors, position the hoses aside, then disconnect the electrical connector.
   Refer to: Quick Release Coupling (310-00A Fuel System - General Information - 2.3L EcoBoost (201kW/273PS), General Procedures).
   

1. NOTE: Note the position of the fuel pump and sender unit for installation.

   Using the special tool remove the lock ring and the fuel pump and sender unit.
   Use Special Service Tool: 310-123  Locking Ring, Fuel Tank.

1. Lift the Fuel Pump and Sender unit slightly and disconnect the vapor line.
   Refer to: Quick Release Coupling (310-00A Fuel System - General Information - 2.3L EcoBoost (201kW/273PS), General Procedures).
   

1. NOTICE: Take extra care not to damage the fuel tank level sensor and float arm.

   Remove and discard the O-ring.
   

Installation

1. NOTICE: Take extra care not to damage the fuel tank level sensor and float arm.

   Reconnect the vapor line.
   Refer to: Quick Release Coupling (310-00A Fuel System - General Information - 2.3L EcoBoost (201kW/273PS), General Procedures).
   

1. NOTE: Use new O-Ring Seal.

   NOTE: Make sure that the seal is correctly located.

1. NOTE: Make sure that the location marks are aligned.

1. To install, reverse the removal procedure.