Focus L4-2.0L (2009)
Fuel Level Sensor: Service and Repair
Fuel Pump Module
Fuel Pump Module
Removal and Installation
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: 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.
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.
1. Remove the fuel tank. For additional information, refer to Fuel Tank See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal
and Replacement/Fuel Tank.
2. NOTE: Clean the Fuel Pump (FP) module connections, couplings, flange surfaces and the immediate surrounding area of any dirt or foreign
material.
Disconnect the fuel supply tube-to-FP module quick connect coupling.
3. NOTICE: Carefully remove the lock ring to avoid damage to the Fuel Pump (FP) module.
Using a suitable lock ring remover tool, rotate the lock ring counterclockwise and remove.
4. NOTICE: The Fuel Pump (FP) module must be handled carefully to avoid damage to the float arm.
NOTE: The FP module will have residual fuel remaining internally, drain into a suitable container.
Remove the FP module from the fuel tank.
5. NOTE: Inspect the mating surfaces of the FP module flange and the 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 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 new O-ring seal.
Remove and discard the FP module O-ring seal.
6. To install, reverse the removal procedure.
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Install a new FP module O-ring seal.
