Expedition

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





5. Disconnect fuel filler and vent hoses from fuel tank. Refer to Figure 1.

6. Disconnect rear EVAP hose from top of fuel tank. See Figure 1.

7. Support fuel tank with adjustable jack.

8. Remove fuel tank straps retaining bolts. The skid plate, fuel tank and straps will be removed as an assembly.

9. Slightly lower fuel tank.





10. Disconnect fuel supply and return lines from top of fuel tank. See Figure 2.





11. Disconnect fuel pump electrical connector, located between the side of the fuel tank and the frame rail. See Figure 3.

12. Slightly lower fuel tank again.

13. Disconnect front EVAP hose from top of fuel tank.

14. Remove fuel tank from vehicle.

15. Clean area around fuel pump to prevent foreign material from entering fuel tank. Refer to Figure 4.

16. Place alignment mark across fuel pump and fuel tank. This will correctly align the fuel pump during reassembly.





17. Remove fuel pump lock-ring, then remove fuel pump. See Figure 4.

18. Remove and discard fuel pump seal.





19. Disconnect fuel sender electrical connectors. Refer to Figure 5.

20. Remove fuel sender retaining screws, then remove fuel sender. See Figure 5.

NOTE:
On some vehicles this step may have already been performed.

CAUTION
Do not cut the main 14 gauge pump ground wire.





21. Cut a section out of the 18 gauge black grounding wire. See Figure 6. Discard removed black wire.

22. Install new fuel sender on the fuel pump. Tighten screws to 2 Nm (18 lb/in). Note the revised orientation of the float.

NOTE:
There are two (2) different terminal end types used on the fuel sender ground wire, a box terminal or a ring terminal. These terminal ends are connected to different locations on the fuel sender.

23. Connect fuel sender electrical connectors as follows:





^ Connect box type terminal end ground wire to location shown in Figure 7.





^ Connect ring type terminal end ground wire to location shown in Figure 8.

^ Reconnect yellow wire to pump sending unit harness.

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

25. Install new seal onto fuel pump-to-gas tank mating surface.

26. Install fuel pump. Align marks made during disassembly. Tighten lock-ring to 44 Nm (33 lb/ft).

27. Position fuel tank under vehicle.

28. Raise fuel tank enough to connect front EVAP hose.

29. Connect front EVAP hose.

30. Raise fuel tank enough to connect fuel lines.

31. Connect fuel supply and return lines.

32. Connect fuel pump electrical connector.

33. Raise fuel tank to installed position.

34. Install fuel tank strap retaining bolts. Tighten bolts to 46-63 Nm (33-46 lb/ft).

35. Remove jack.

36. Connect rear EVAP hose to top of fuel tank.

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

38. Refill fuel tank. It may be necessary to refill fuel tank before connecting filler hose.

39. Lower vehicle.

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

41. Stan and run engine.

42. Raise vehicle.

43. Inspect fuel system for leaks.

44. Lower vehicle.