Fuel tank removal/fuel pump removal - FLSTF - FLSTFI Fat Boy Harley Davidson Motorcycles

You must remove the fuel tank to replace the fuel pump.

1. Remove fuel tank.
   
2. Remove any dirt that has accumulated around fuel pump module retaining flange.
   
3. Turn fuel pump module locking retainer ring (#1)counterclockwise using Fuel Tank Sender Wrench 310-D006 and remove fuel pump module locking retainer ring.
   
4. Pull fuel pump module sender plate up out of fuel tank until locking tabs(#3) for fuel pump module are accessible. Reach through fuel pump module opening, squeeze both locking tabs together and remove fuel pump module from fuel tank.

Fuel Pump - Multi-Port Fuel Injection models REMOVAL & INSTALLATION 1984-95 Models Fig. 1: Loosen the hose clamps and tag the fuel hoses before disconnecting them . . .
Fig. 2: . . . then detach the hoses from the fuel pump module/sending unit
Fig. 3: Disengage the fuel pump module/sending unit wiring harness connector

1. Disconnect the negative battery cable.
2. Remove the fuel tank filler cap.
3. Relieve the fuel system pressure as outlined in this section.
4. Drain the fuel from the fuel tank.
5. Raise and support the rear end on jackstands.
6. Remove the fuel inlet and outlet hoses from the sending unit. Be ready to catch any spilled fuel.
7. Disengage the sending unit wires. Fig. 4: The fuel pump module/sending unit retaining ring must be rotated counterclockwise for removal
   
   
8. Using a brass punch and hammer, remove the sending unit retaining lockring by tapping it counterclockwise. Fig. 5: Carefully pull the fuel pump module/sending unit out of the fuel tank - step shown with the fuel tank mounted on the vehicle
   Fig. 6: Remove and discard the fuel pump module O-ring gasket
   
   
9. Remove the sending unit, which incorporates the electric fuel pump, along with the O-ring seal from the fuel tank. Discard the O-ring.
10. Remove and discard the pump inlet filter.
11. Disengage the fuel pump terminal wires.
12. Remove the pump outlet hose and clamp.
13. Unfasten the pump top mounting bracket nut and remove the pump. To install:
    
14. Install a new inlet filter on the pump. Fig. 7: This is the proper positioning of the fuel pump module assembly inside the fuel tank
    
    
15. Assemble the pump and bracket. Connect the hose and wiring.
16. Install the unit and new O-ring in the tank. The rubber stopper on the end of the fuel return tube must be inserted into the cup in the fuel tank reservoir.
17. Install the lockring. Carefully tap it into place until it seats against the stop on the tank.
18. Connect the hoses.
19. Engage the wiring.
20. Lower the vehicle, fill the tank, run the engine and check for leaks.

1996-98 Models Fig. 8: Fuel pump module location - 1996 model shown

1. Drain and remove the fuel tank as outlined in this section.
2. Using tool 6856 or its equivalent, remove the module locknut which is threaded onto the fuel tank. The module will spring up when the nut is removed.
3. Remove the module. To install:
   
4. Install a new gasket and place the module into the opening in the fuel tank.
5. Position a new locknut on top of the module and tighten the nut using tool 6856 or its equivalent to 40 ft. lbs. (54 Nm).
6. Install the fuel tank as outlined in this section. Fig. 9: Locknut removal using tool 6856 or its equivalent
   Fig. 10: Install a new gasket on the fuel tank opening
   

There is none:

Fuel Tank & Fuel Pump Module Assembly Removal & Installation To Remove:

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Shift the vehicle into NEUTRAL and position it on a hoist.
3. Release the fuel pressure.
4. Disconnect the negative battery cable.
5. Remove the fuel tank filler cap.
6. Drain as much fuel from the tank as possible.
7. Using suitable hose pinching pliers, clamp the fuel tank filler hose. Clamp the fuel tank filler hose in the location shown
   
   
8. Disconnect the three quick connect couplings from the fuel tank tubes at the tank.
9. Disconnect the fuel pump electrical connector.
10. Disconnect the fuel filter inlet tube from the filter.
11. Position a suitable lifting device under the fuel tank.
12. Remove the two fuel tank support strap bolts.
13. Lower the fuel tank to access the fuel pump module while swinging the fuel tank support straps away from the tank.
14. Clean the area around the fuel pump mounting flange.
15. Disconnect the fuel pump module electrical connector and the fuel pump module fuel outlet tube.
16. Using the special tool, turn the fuel pump module retaining ring counterclockwise and remove it. CAUTION
    The fuel pump module must be handled carefully to avoid damage to the float arm, filter and convolute hoses.
    
17. Turn the fuel pump module counterclockwise and the fuel pump module will release from the locking tabs. Remove the fuel pump module from the fuel tank.

To Install:

1. Install the fuel pump module in the fuel tank.
2. Connect the fuel pump module electrical connector and the fuel pump module fuel outlet tube.
3. Raise the tank into position and install the mounting strap bolts. Tighten the bolts to 26 ft-lbs (35 Nm).
4. Connect the fuel lines and electrical connectors at the fuel tank.
5. Lower the vehicle and refill the tank.
6. Connect the negative battery cable.
7. Turn the ignition key to the ON position to pressurize the fuel system.
8. Visually inspect the fuel system for leaks.

Removal & Installation
To Remove:

1. Properly relieve the fuel system pressure.
   
2. Drain the fuel tank through the filler pipe.
   
3. Support the fuel tank.
   
4. Remove or disconnect the following:
   
   
   
   • Negative battery cable
     
   • Filler neck
     
   • Shield and tank straps
     
   • Fuel lines and vapor hose from pump and tank
     
   • Electrical connection from fuel pump
     
   • Fuel tank
     
   • Fuel pump/sending unit assembly by turning the locking ring (located on top
     of the fuel tank) counterclockwise using a spanner wrench
     
   • Fuel pump from the fuel lever sending device

To Install:

1. Install or connect the following:
   
   
   
   • Fuel pump in tank with new seal around opening
     
   • Tank and connect fuel lines and vapor hose
     
   • Tank to the frame
     
     
     
     1. Torque to: 33 ft. lbs. (45 Nm)
     
     
   • Shield
     
   • Fuel filler neck and clamp
     
   • Negative battery cable
   
   
2. Refill the tank.
   
3. Run the engine and check for leaks.

View of the in-tank fuel pump assembly.

Removal & Installation To Remove:

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Shift the vehicle into NEUTRAL and position it on a hoist.
3. Release the fuel pressure.
4. Disconnect the negative battery cable.
5. Remove the fuel tank filler cap.
6. Drain as much fuel from the tank as possible.
7. Using suitable hose pinching pliers, clamp the fuel tank filler hose. Clamp the fuel tank filler hose in the location shown
   
   
8. Disconnect the three quick connect couplings from the fuel tank tubes at the tank.
9. Disconnect the fuel pump electrical connector.
10. Disconnect the fuel filter inlet tube from the filter.
11. Position a suitable lifting device under the fuel tank.
12. Remove the two fuel tank support strap bolts.
13. Lower the fuel tank to access the fuel pump module while swinging the fuel tank support straps away from the tank.
14. Clean the area around the fuel pump mounting flange.
15. Disconnect the fuel pump module electrical connector and the fuel pump module fuel outlet tube.
16. Using the special tool, turn the fuel pump module retaining ring counterclockwise and remove it. CAUTION
    The fuel pump module must be handled carefully to avoid damage to the float arm, filter and convolute hoses.
    
17. Turn the fuel pump module counterclockwise and the fuel pump module will release from the locking tabs. Remove the fuel pump module from the fuel tank.

To Install:

1. Install the fuel pump module in the fuel tank.
2. Connect the fuel pump module electrical connector and the fuel pump module fuel outlet tube.
3. Raise the tank into position and install the mounting strap bolts. Tighten the bolts to 26 ft-lbs (35 Nm).
4. Connect the fuel lines and electrical connectors at the fuel tank.
5. Lower the vehicle and refill the tank.
6. Connect the negative battery cable.
7. Turn the ignition key to the ON position to pressurize the fuel system.
8. Visually inspect the fuel system for leaks.

1. Remove fuel tank.
   
2. Remove any dirt that has accumulated around fuel pump module retaining flange.
   
3. Turn fuel pump module locking retainer ring (#1)counterclockwise using Fuel Tank Sender Wrench 310-D006 and remove fuel pump module locking retainer ring.
   
4. Pull fuel pump module sender plate up out of fuel tank until locking tabs(#3) for fuel pump module are accessible. Reach through fuel pump module opening, squeeze both locking tabs together and remove fuel pump module from fuel tank.
   

REMOVAL PROCEDURE

1. Disconnect the negative battery cable.
2. Drain all the fuel from the tank.
3. Install and tighten the drain plug. Tighten Tighten the drain plug to 20 N.m (14 lb ft.) .
4. Remove the fuel tank.
5. Remove the retaining screws from the fuel tank.
6. Remove the fuel pump assembly from the fuel tank.
   1. Cover the fuel pump opening in order to prevent dust, dirt, or debris from entering the fuel tank.
   INSTALLATION PROCEDURE
   
   
   1. Install the fuel pump assembly. Tighten Tighten the fuel pump assembly mounting bolts to 3 N.m (27 lb ft.) .
   2. Install the fuel pump assembly retaining screws.
   3. Install the fuel tank assembly.
   4. Fill the tank with fuel.
   5. Tighten the fuel filler cap.
      1. Connect the negative battery cable.
      REMOVAL PROCEDURE # 2
      REMOVAL
      
      CAUTION: When repair to the fuel system has been completed, start engine and check the fuel system for loose connection or leakage. For the fuel system diagnosis, see Computers and Control Systems/System Diagnosis.
      
      
      1. Disconnect battery ground cable.
      2. Loosen fuel filler cap.
      3. Drain fuel. Tighten drain plug to the specified torque after draining fuel. Torque: 20 N.m (14 lb ft) - M8
      4. Remove fuel tank assembly (1).
      5. Remove fuel pump (FP) assembly (2) fixing screws and remove the FP assembly.
      NOTE: After removing FP, cover fuel tank to prevent any dust entering.
      INSTALLATION
      
      1. Install FP assembly (2).
      2. Install fuel tank assembly (1).
      3. Fill the tank with fuel and tighten fuel filler cap.
      4. Connect battery ground cable.

2001 Ford Taurus V6-3.0L DOHC VIN S
Fuel Pump: Service and Repair

REMOVAL
1. Remove the fuel tank.
2. Clean the area around the fuel pump mounting flange.
3. Using the special tool, remove the fuel module retaining ring.(Screwdriver and hammer)
4. Remove the fuel delivery module from the fuel tank.
CAUTION: The fuel delivery module must be handled carefully to avoid damage to the float arm, filter, and convolute hoses.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: A stop should be felt when aligning the raised arrow on top of the fuel tank delivery module to the dot on the fuel tank.

I believe this is same truck as Ranger

Pump is in tank

Removal
NOTE: On some vehicles, fuel gauge sending unit is not available separately. On those vehicles, to replace sending unit, replace entire fuel pump .

1. Remove fuel tank as described in this section.

Removal and Installation
NOTE: Make sure fuel tank is properly supported during removal and installation procedures.

1. Drain fuel from fuel tank .

1. Loosen fill pipe clamp.

1. Remove bolts securing shield and bracket assembly to frame (5005) and remove assembly from vehicle.

1. Remove fuel tank filler pipe from vehicle.

1. Support fuel tank .

1. Remove bolts and nuts from rear fuel tank support strap and remove rear fuel tank support strap .

1. Remove bolt and nut from front fuel tank support strap and remove front fuel tank support strap .

1. Lower fuel tank .

1. Remove fuel feed hose at sender push connector.

1. Remove fuel return hose at sender unit push connector.

1. Disconnect sender and fuel pump electrical connector.

1. Remove fuel vapor hose from fuel vapor valve .

1. Lower fuel tank from vehicle

1. Remove fuel tank to bench. Remove any dirt that has accumulated around the fuel pump attaching flange so that it will not enter the fuel tank during fuel pump removal.

1. Turn the fuel tank sending unit locking retainer ring (9A307) counterclockwise with the Fuel Tank Lock Ring Wrench Tool T90T-9275-A or T86T-9275-A and remove fuel tank sending unit locking retainer ring .

1. Remove the fuel pump and sender assembly.

1. Remove fuel pump mounting gasket (9417) and discard.

1. If necessary, disconnect spade connector and remove two screws and fuel gauge sending unit.

The combination Fuel Filter/Fuel Pressure Regulator is located on the fuel pump module. The fuel pump module is located on top of fuel tank.

The filter/regulator may be removed without removing fuel pump module although fuel tank must be removed.

REMOVAL

1. Remove fuel tank. Refer to Fuel Tank Removal/Installation.
2. Clean area around filter/regulator.
3. Disconnect fuel line at filter/regulator. Refer to Quick-Connect Fittings for procedures.
4. Remove retainer clamp from top of filter/regulator. Clamp snaps to tabs on pump module. Discard old clamp.
5. Pry filter/regulator from top of pump module with 2 screwdrivers. Unit is snapped into module
6. Discard gasket below filter/regulator.
   1. Before discarding filter/regulator assembly, inspect assembly to verify that O-rings are intact. If the smallest of the two O-rings can not be found on bottom of filter/regulator, it may be necessary to remove it from the fuel inlet passage in fuel pump module.
   INSTALLATION
   
   1. Clean recessed area in pump module where filter/regulator is to be installed.
   2. Obtain new filter/regulator (two new O-rings should already be installed)
   3. Apply a small amount of clean engine oil to O-rings. Do not install O-rings separately into fuel pump module. They will be damaged when installing filter/regulator.
   4. Install new gasket to top of fuel pump module.
   5. Press new filter/regulator into top of pump module until it snaps into position (a positive click must be heard or felt).
   6. The arrow molded into top of fuel pump module should be pointed towards front of vehicle (12 O'clock position).
   7. Rotate filter/regulator until fuel supply tube (fitting) is pointed towards front of vehicle (12 O'clock position).
   8. Install new retainer clamp (clamp snaps over top of filter/regulator and locks to flanges on pump module).
   9. Connect fuel line at filter/regulator. Refer to Quick-Connect Fittings for procedures.
   10. Install fuel tank. Refer to Fuel Tank Removal/Installation.

WARNING: THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE EVEN WITH THE ENGINE OFF. THIS PRESSURE MUST BE RELEASED BEFORE SERVICING FUEL TANK .

Two different procedures may be used to drain fuel tank (lowering tank or using DRB scan tool).

The quickest draining procedure involves lowering the fuel tank.

As an alternative procedure, the electric fuel pump may be activated allowing tank to be drained at fuel rail connection. Refer to DRB scan tool for fuel pump activation procedures. Before disconnecting fuel line at fuel rail, release fuel pressure. Refer to the Fuel System Pressure Release Procedure for procedures. Attach end of special test hose tool number 6541, 6539, 6631 or 6923 at fuel rail disconnection (tool number will depend on model and/or engine application). Position opposite end of this hose tool to an approved gasoline draining station. Activate fuel pump and drain tank until empty.

If electric fuel pump is not operating, tank must be lowered for fuel draining. Refer to following procedures.

FUEL TANK REMOVAL

1. Disconnect negative battery cable at battery.
2. Release fuel system pressure. Refer to the Fuel System Pressure Release.
3. Raise and support vehicle.
4. If Equipped: Remove fuel tank skid plate.
5. Remove 4 fuel hose shield mounting bolts and remove fuel hose shield from body.
   1. Remove fuel tank fill hose and vent hose clamps at fuel tank filler tube. Remove both hoses at fuel filler tube.
   2. Remove exhaust tailpipe heat shield mounting bolts and remove shield. CAUTION: To protect fuel tank from exhaust heat, this shield must reinstalled after tank installation.
   3. Place a hydraulic jack to bottom of fuel tank. WARNING: PLACE A SHOP TOWEL AROUND FUEL LINES TO CATCH ANY EXCESS FUEL .
      1. Disconnect fuel supply line from fuel extension line near front of fuel tank. Refer to Fuel Tubes/Lines/Hoses and Clamps. Also refer to Quick-Connect Fittings for procedures.
      2. Disconnect EVAP canister vent line near front of tank.
      3. Disconnect fuel pump module electrical connector (pigtail harness) near front of tank. Harness connector is clipped to body.
         1. Remove two fuel tank strap nuts. Position both tank support straps away from tank.
         2. Carefully lower right side of tank while feeding both fuel hoses through access hole in body. Fuel Tank Full And Not Drained Using DRB Scan Tool: To prevent fuel loss through hoses, keep left side of tank higher than right side while lowering. Do not allow hose openings to drop lower than top of tank.
         3. Continue lowering tank until clear of vehicle. Place tank on floor with left side (hose side) higher than right side
            1. Drain tank by removing fuel fill hose at tank. Fuel fill hose is largest of 2 hoses. Insert the drain hose (from an approved gasoline draining station) into hose opening. Drain tank until empty.
            2. If fuel pump module removal is necessary, refer to Fuel Pump Module Removal/installation for procedures.
            INSTALLATION
            
            1. If fuel pump module is being installed, refer to Fuel Pump Module Removal/installation for procedures.
            2. Install fuel fill/vent hoses to tank fittings. To prevent hose from kinking, rotate each hose until index mark on hose is aligned to index tang on fuel tank.
            3. Install hose clamps to hoses. Position clamps between index marks on each hose.
            4. Position fuel tank to hydraulic jack.
            5. Raise tank into position while guiding fuel fill and vent hoses into and through access hole in body.
            6. Continue raising tank until positioned to body.
            7. Attach two fuel tank mounting straps and mounting nuts. Tighten nuts to 10 Nm (90 in. lbs.) torque. Do not over tighten nuts.
            8. Install both fuel hoses to fuel fill tube. Tighten both retaining clamps.
            9. Position fuel hose shield to body. Install and tighten 4 mounting bolts.
            10. Connect fuel pump module pigtail harness electrical connector near front of tank.
            11. Connect fuel pump module supply line near front of tank. Refer to Quick-Connect Fittings for procedures.
            12. Connect EVAP hose near front of tank.
            13. Install exhaust tailpipe heat shield.
            1. Install fuel tank skid plate (if equipped).
            1. Lower vehicle and connect battery cable to battery.