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Home >> Ford >> 2012 >> Mustang V8-5.4L SC >> Repair and Diagnosis >> Powertrain Management >> Fuel Delivery and Air Induction >> Fuel Tank >> Service and Repair >> Procedures

Procedures




Fuel Tank Draining









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 are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.

WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

3.7L, 5.0L (4V) and 5.4L (4V) vehicles

1. Release the fuel system pressure. For additional information, refer to Fuel System Pressure Release Service and Repair.

2. Disconnect the battery ground cable.

3. NOTE: The supplemental refueling adapter is located in the luggage compartment.
Install the supplemental refueling adapter and a length of semi-rigid fuel drain tube into the Easy FuelTM (capless) fuel tank filler pipe until the tube enters the fuel tank.






4. NOTE: This step is to remove approximately one-eighth tank of the fuel from a completely full fuel tank and the majority of any residual fuel in the fuel tank filler pipe, lowering the fuel level below the Fuel Pump (FP) module mounting flange.
Attach the Fuel Storage Tanker to the fuel drain tube and remove approximately one-eighth (approximately 2 gallons) of fuel from the tank.


5. If equipped, remove the rear support braces. For additional information, refer Frame.

3.7L and 5.0L (4V) vehicles

6. Lower the fuel tank.
1. Lift the vehicle.

2. Support the fuel tank.

3. Remove the fuel tank strap bolts.
- Tighten to 52 Nm (38 lb-ft).

4. By hand, reinstall the fuel tank strap bolts three full turns.

5. Remove the fuel tank support.

6. Lower the vehicle.


3.7L, 5.0L (4V) and 5.4L (4V) vehicles

7. Remove the rear seat cushion.

8. Remove the FP (Fuel Pump) module and fuel level sensor access covers and position aside.





3.7L and 5.0L (4V) vehicles

9. NOTE: Clean the FP (Fuel Pump) module connections, couplings, flange surfaces and the immediate surrounding area of any dirt or foreign material.
Disconnect the FP (Fuel Pump) module electrical connector.






5.4L (4V) vehicles

10. NOTE: Clean the FP (Fuel Pump) module connections, couplings, flange surfaces and the immediate surrounding area of any dirt or foreign material.
Disconnect the FP (Fuel Pump) module electrical connector.






3.7L and 5.0L (4V) vehicles

11. NOTE: Place absorbent pads in the general work area in case of fuel spillage.

Disconnect the rear fuel tube-to-FP (Fuel Pump) module quick connect coupling.





5.4L (4V) vehicles

12. NOTE: Place absorbent pads in the general work area in case of fuel spillage.

Disconnect the rear fuel tube-to-FP (Fuel Pump) module quick connect coupling.





3.7L and 5.0L (4V) vehicles

13. NOTICE: Carefully install the Fuel Tank Sender Unit Socket to avoid damage to the Fuel Pump (FP) module when removing the lock ring.

NOTE: When installing the FP (Fuel Pump) module, install a new O-ring seal.
Install the Fuel Tank Sender Unit Socket and remove the FP (Fuel Pump) module lock ring.






5.4L (4V) vehicles

14. NOTICE: Carefully install the Fuel Tank Sender Unit Socket to avoid damage to the Fuel Pump (FP) module when removing the lock ring.

NOTE: When installing the FP (Fuel Pump) module, install a new O-ring seal.
Install the Fuel Tank Sender Unit Socket and remove the FP (Fuel Pump) module lock ring.






3.7L, 5.0L (4V) and 5.4L (4V) vehicles

15. NOTICE: The Fuel Pump (FP) module must be handled carefully to avoid damage to the float arm.

Position the FP (Fuel Pump) module aside. Using the Fuel Storage Tanker, completely drain the remaining fuel from the LH saddle of the fuel tank.






16. NOTE: Inspect the surfaces of the FP (Fuel Pump) module flange and fuel tank O-ring seal contact surfaces. Do not polish or adjust the O-ring seal contact area of the fuel tank flange or the fuel tank. Install a new FP (Fuel Pump) module or fuel tank if the O-ring seal contact area is bent, scratched or corroded.

NOTE: To install, apply clean engine oil to the O-ring seal.
Remove and discard the FP (Fuel Pump) module O-ring seal.


17. NOTE: Clean the fuel level sensor connections, flange surfaces and the immediate surrounding area of any dirt or foreign material.
Disconnect the fuel level sensor electrical connector.






3.7L and 5.0L (4V) vehicles

18. NOTICE: Carefully install the Fuel Tank Sender Unit Socket to avoid damage to the fuel level sensor when removing the lock ring.

NOTE: When installing the fuel level sensor, install a new O-ring seal.
Install the Fuel Tank Sender Unit Socket and remove the fuel level sensor lock ring.






5.4L (4V) vehicles

19. NOTICE: Carefully install the Fuel Tank Sender Unit Socket to avoid damage to the fuel level sensor when removing the lock ring.

NOTE: When installing the fuel level sensor, install a new O-ring seal.
Install the Fuel Tank Sender Unit Socket and remove the fuel level sensor lock ring.






3.7L, 5.0L (4V) and 5.4L (4V) vehicles

20. NOTICE: The fuel level sensor must be handled carefully to avoid damage to the float arm.

Position the fuel level sensor aside. Using the Fuel Storage Tanker, completely drain the RH saddle of the fuel tank.






21. NOTE: Inspect the surfaces of the fuel level sensor flange and fuel tank O-ring seal contact surfaces. Do not polish or adjust the O-ring seal contact area of the fuel tank flange or the fuel tank. Install a new fuel level sensor or fuel tank if the O-ring seal contact area is bent, scratched or corroded.

NOTE: To install, apply clean engine oil to the O-ring seal.
Remove and discard the fuel level sensor O-ring seal.

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