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Use this test in conjunction with the Fuel Pump Pressure Test and Fuel Pump Capacity Test. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine OFF) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately (1 – 2 seconds) rise to specification. Abnormally long periods of cranking to restart a hot engine that has been shut down for a short period of time may be caused by: Fuel pressure bleeding past a fuel injector(s). Fuel pressure bleeding past the check valve in the fuel pump module. 1. Disconnect the fuel inlet line at fuel rail. Refer to Fuel Tubes/Lines/Hoses and Clamps for procedures. On some engines, air cleaner housing removal may be necessary before fuel line disconnection. 2. Obtain correct Fuel Line Pressure Test Adapter Tool Hose. Tool number 6539 is used for 5/16″ fuel lines and tool number 6631 is used for 3/8″ fuel lines. Fig.7 Connecting Adapter Tool (Typical) 3. Connect correct Fuel Line Pressure Test Adapter Tool Hose between disconnected fuel line and fuel rail (Fig. 7). 4. Connect the 0 – 414 kPa (0 – 60 psi) fuel pressure test gauge (from Gauge Set 5069) to the test port on the appropriate Adaptor Tool. The DRB III Scan Tool along with the PEP module, the 500 psi pressure transducer, and the transducer-to-test port adapter may also be used in place of the fuel pressure gauge. The fittings on both tools must be in good condition and free from any small leaks before performing the proceeding test. 5. Start engine and bring to normal operating temperature. 6. Observe test gauge. Normal operating pressure should be 339 kpa ±34 kPa (49.2 psi ±5 psi) . 7. Shut engine OFF. 8. Pressure should not fall below 30 psi for five minutes . 9. If pressure falls below 30 psi , it must be determined if a fuel injector, the check valve within the fuel pump module, or a fuel tube/line is leaking. 10. Again, start engine and bring to normal operating temperature. 11. Shut engine OFF. 12. Testing for fuel injector or fuel rail leakage: Clamp OFF the rubber hose portion of Adaptor Tool between the fuel rail and the test port “T” on Adapter Tool. If pressure now holds at or above 30 psi , a fuel injector or the fuel rail is leaking.

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WARNING: The fuel system may be under a constant pressure (even with the engine off). Before servicing the fuel pump module, the fuel system pressure must be released. 1. Perform the fuel system pressure release procedure See: Fuel Pressure Release\Service and Repair 2. Disconnect and isolate the negative battery cable (1). 3. Raise and support vehicle. 4. Perform the fuel tank draining procedure See: Procedures 5. Disconnect the electrical connector from ESIM switch (4). 6. Disconnect the quick-connect fitting at the front of the fuel tank (10). 7. Disconnect the quick-connect fitting (8) at the rear of the fuel tank. 8. Loosen the fill hose retaining clamp (9) at the rear of the fuel tank and disconnect the fill hose. 9. Using a suitable hydraulic jack with a fuel tank adapter, support the fuel tank. 10. Remove the two fuel tank support strap retaining nuts (5) and remove both fuel tank support straps (4). 11. Carefully lower the fuel tank a few inches and disconnect the fuel pump module electrical connector. 12. Disconnect the fuel line quick-connect fitting at the fuel pump module. 13. Lower the fuel tank and remove from hydraulic jack. 14. If fuel pump module removal is necessary See: Fuel Pump\Service and Repair\Fuel Pump Module – Removal

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Removal 1. Remove fuel tank (9002) as described. 2. Remove any dirt that has accumulated around fuel pump module retaining flange. 3. Turn fuel pump module locking retainer ring counterclockwise using Fuel Tank Sender Wrench 310-002 (T74P-9275-A) and remove fuel pump module locking retainer ring. 4. Pull fuel pump module sender plate up out of fuel tank until locking tabs 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 . 5. Remove O-ring seal and discard. Installation 1. Clean fuel pump module retaining flange, fuel tank mounting surface and seal ring groove. 2. Apply a light coating of Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-BA on a new O-ring seal to hold it in place during assembly and install O-ring in seal ring groove. 3. Install fuel pump module carefully into fuel tank to make sure that filter, hoses and float rod are not damaged or binding. Align fuel pump module and fuel tank retainer and push fuel pump module into fuel tank retainer. A definite click will be heard when the two tabs on fuel pump module engage the fuel tank retainer. The fuel pump module must be snapped in the retainer with both tabs. Pull on fuel pump module to make sure it is fully engaged. Install fuel pump module sender plate to fuel tank , being careful that locating keys are in keyways and O-ring seal remains in place. 4. Hold assembly in place and install fuel pump module locking retainer ring finger-tight. Make sure that all locking tabs are under fuel pump module locking retainer ring tabs. 5. Secure fuel pump module unit by rotating fuel pump module locking retainer ring clockwise using Fuel Tank Sender Wrench 310-002 (T74P-9275-A) until fuel pump module locking retainer ring contacts the stops. 6. Install fuel tank in vehicle as described. 7. Lower vehicle. 8. Install a minimum of 38 liters (10 gallons) of fuel. Check for leaks. 9. Turn ignition switch to RUN position for three seconds repeatedly (5 to 10 times) until Multiport Fuel Injection (MFI) Fuel Pressure Gauge 310-012 (T80L-9974-B) or equivalent (depending upon application) shows at least 207 kPa (30 psi). Check for leaks at fittings. 10. Remove Multiport Fuel Injection (MFI) Fuel Pressure Gauge 310-012 (T80L-9974-B) or equivalent (depending upon application), start engine and recheck for leaks.

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1. If fuel pump module installation is necessary See: Fuel Pump\Service and Repair\Fuel Pump Module – Installation 2. Secure the fuel tank onto a suitable hydraulic jack with a fuel tank adapter. 3. Raise and position the fuel tank leaving room to make the connections at the top of the fuel tank. 4. Connect the fuel supply line (6) to the fuel pump module. 5. Connect the electrical connector (5) to the fuel pump module. 6. Raise the fuel tank (1) until snug to the body. 7. Install the fuel tank straps (4). 8. Install the strap nuts (5) and tighten to 41 Nm (30 ft. lbs.). 9. Remove the hydraulic jack. 10. Connect the electrical connector to the ESIM switch (4). 11. Connect the quick-connect fitting at the front of the fuel tank (10). 12. Connect the quick-connect fitting (8) at the rear of the fuel tank. 13. Connect the fill hose (7) at the rear of the fuel tank and securely tighten the fill hose retaining clamp (9).

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WARNING: WHEN DRAINING FUEL FROM THE FUEL TANK, KEEP SPARKS, SMOKING MATERIALS, AND OPEN FLAMES AWAY FROM THE VEHICLE. WARNING: THE FUEL SYSTEM CONTAINS PRESSURIZED FUEL AFTER THE VEHICLE IS SHUT DOWN AND WILL MAINTAIN THE PRESSURE FOR A LONG PERIOD OF TIME. 1. Relieve the fuel pressure; refer to Section 310-00. 2. Disconnect the battery ground cable (14301); refer to Section 414-01. 3. Raise and support the vehicle; refer to Section 100-02. 4. Disconnect the fuel tank filler pipe hose (9047) from the fuel tank (9002). 5. Drain the fuel from the fuel tank (9002); refer to Section 310-00. 6. Disconnect the fuel tank vent tube (9A228) from fuel tank filler pipe (9034). 7. Disconnect the fuel pump electrical connector. 8. If equipped, remove fuel tank skid plate. 1. Remove the five fuel tank skid plate bolts. 2. Lower the fuel tank skid plate. 9. Position a suitable jack under the fuel tank (9002). 10. Remove the front fuel tank support strap (9092). 1. Remove the two bolts. 2. Remove the front fuel tank support strap (9092). 11. Remove the rear fuel tank support strap (9092). 1. Remove the three bolts. 2. Remove the rear fuel tank support strap. 12. Partially lower the fuel tank and disconnect the two EVAP emissions hoses. 13. Remove the two safety clips from the fuel lines. 14. Disconnect the fuel lines from the fuel pump (9350). 1. Install and push the (A) fuel line disconnect tool into the (B) female fitting. 2. Separate the male and female fitting. 15. Remove the fuel tank. 16. Remove the fuel pump. 1. Remove the fuel pump locking retaining ring (9C385). 2. Remove the fuel pump and discard the O-ring. Installation 1. Install the fuel pump (9350). 1. Install a new O-ring and fuel pump (9350). 2. Install the fuel pump locking retainer ring (9C385). 2. With a suitable jack, position the fuel tank (9002). 3. Connect the fuel lines. 4. Connect the safety clips. 5. Connect the EVAP emissions hoses.