Explorer/Mountaineer

1. Install memory saver, then disconnect battery negative cable.

2. Remove fuel system pressure as follows:

^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge.

^ Slowly open manual valve on fuel pressure gauge to relieve fuel system pressure.

3. Raise and support vehicle.

4. Remove skid plate retaining bolts, then the skid plate.

5. Completely drain fuel tank. It may be necessary to disconnect fuel filler hose to drain fuel tank.

6. Support fuel tank with adjustable jack.

7. Disconnect fuel filler and vent hoses from fuel tank.

8. Remove fuel tank strap retaining bolt.

9. Remove fuel tank-to-front support bracket retaining bolts.

10. Slightly lower fuel tank. Push fuel tank back until lip of tank clears support bracket.





11. Disconnect fuel supply, return and vapor lines from top of fuel tank. See Figure 6.





12. Disconnect fuel pump electrical connector, located in frame rail. See Figure 7.

13. Remove fuel tank from vehicle.





14. Disconnect fuel tank pressure transducer electrical connector. Refer to Figure 8.

15. Clean area around fuel pump to prevent foreign material from entering fuel tank.

16. Place alignment mark across fuel pump and fuel tank. This will assure correct alignment of fuel pump during assembly.

17. Remove fuel pump retaining screws, then remove fuel pump. See Figure 8.





18. Disconnect fuel sender electrical connectors. Refer to Figure 9.

19. Remove fuel sender retaining screws, then remove fuel sender. See Figure 9.

20. Install new fuel sender on fuel pump. Tighten screws to 2 Nm (18 lb/in).

21. Connect fuel sender electrical connectors. Make sure wires are routed correctly.

22. Clean fuel pump-to-gas tank mating surface.

23. Install fuel pump. Align marks made during disassembly. Tighten retaining screws to 9-12 Nm (80-107 lb/in).

24. Connect fuel tank pressure transducer electrical connector.

25. Position fuel tank under vehicle.

26. Raise fuel tank enough to connect fuel lines.

27. Connect fuel supply and return lines.

28. Connect fuel pump electrical connector.

29. Position fuel tank in installed position.

30. Install fuel tank-to-front support bracket retaining bolts. Tighten bolts to 34-46 Nm (25-34 lb/ft).

31. Install fuel tank strap retaining bolt. Tighten bolts to 34-46 Nm (25-34 lb/ft).

32. Remove jack.

33. Connect fuel filler and vent hoses to fuel tank.

34. Install skid plate. Torque retaining bolts to 34-46 Nm (25-34 lb/ft).

35. Lower vehicle.

36. Fill fuel tank.

37. Connect battery negative cable, then remove memory saver.

38. Start and run engine.

39. Raise vehicle.

40. Inspect fuel system for leaks.

41. Lower vehicle.