Section 10-01: Fuel Tank, Filter and Electric Fuel Pump
1994 Mustang Workshop Manual
REMOVAL AND INSTALLATION

Fuel Tank

SPECIAL SERVICE TOOL(S) REQUIRED
Description Tool Number
Fuel Tank Sender Wrench T74P-9275-A

 

Removal

  1. Fuel should be drained from the fuel tank (9002) as outlined.

    Vehicles with fuel injected engines have reservoirs inside the fuel tank to maintain fuel near the fuel pickup during vehicle cornering maneuvers and under low fuel operating conditions. These reservoirs could block siphon tubes or hoses from reaching the bottom of the fuel tank . This situation can be overcome with a few repeated attempts using different hose orientations.

  1. Disconnect fuel hoses and tubes.
  1. On vehicles equipped with a fuel tank filler pipe retainer (9B233) which fastens the fuel tank filler pipe (9034) to the fuel tank , remove the screw retaining the fuel tank filler pipe retainer to the fuel tank flange.
  1. Disconnect electrical hookup to the fuel tank sending unit (9275) . On some vehicles, the electrical connection is inaccessible on top of the fuel tank and no intermediate connection point is provided. In these cases, the electrical connector must be disconnected from the fuel tank sending unit with the fuel tank partially removed from the vehicle.
  1. Place a safety support under the fuel tank . Take care not to deform fuel tank to avoid affecting capacity and/or fuel pickup. Remove the bolts or nuts from one end of the fuel tank support strap (9092) RH and fuel tank support strap LH. The fuel tank support straps are hinged at the other end and can be swung out of the way.
  1. Partially remove the fuel tank and disconnect the fuel lines and electrical connector from the fuel tank sender, if required. Refer to Push Connect Fitting Removal, if so equipped.
  1. Remove fuel tank from the vehicle.




    Item Part Number Description
    1 9002 Fuel Tank
    2 9C385 Fuel Pump Locking Retainer Ring
    3 9350 Fuel Pump
    4 9276 Fuel Tank Sending Unit Gasket
    5 N802060-S190 J-Nut (2 Req'd)
    6 9092 LH Fuel Tank Support Strap LH
    7 9B219 Strap Insulator
    8 9092 RH Fuel Tank Support Strap RH
    9A N605921-S192 Bolt (2 Req'd)
    10 9B007 Fuel Tank Modification Shield and Pipe Kit
    11 9A068 Fuel Tank to Floor Pan Insulator
    12 9B593 Fuel Vapor Valve
    13 9030 Fuel Tank Filler Cap
    14B N805402-S56 Bolt (3 Req'd)
    15 9034 Fuel Tank Filler Pipe
    16 9B233 Fuel Tank Filler Pipe Retainer
    17C W611612-S56 Bolt
    18 N802429-S100 Pin (2 Req'd)
    19 9B212 Fuel Tank Rear Shield
    20 388577-S150 Push Pin (2 Req'd)
    A Tighten to 29-41 Nm (22-30 Lb-Ft)
    B Tighten to 2.3-3.3 Nm (21-29 Lb-In)
    C Tighten to 7.3-9.0 Nm (65-80 Lb-In)
 

Installation

  1. Before proceeding, check the following items:
    1. Leak check the fuel tank sending unit . If necessary, tighten with Fuel Tank Sender Wrench T74P-9275-A.
    1. Ensure fuel vapor valve (9B593) is installed completely on the fuel tank top.
    1. Make all required fuel line, fuel return line, vapor vent and electrical connections which will be inaccessible after the fuel tank is installed.
    1. Replace or install all body mounted fuel tank shields.
  1. Place the fuel tank in its proper position in the vehicle. For most models, lubricate the fuel tank filler pipe with water base tire mounting lubricant. Install the fuel tank onto the filler pipe then bring the fuel tank into final position. Take care not to deform fuel tank to avoid affecting capacity and/or fuel pickup.
  1. Bring fuel tank support strap RH and fuel tank support strap LH around the fuel tank and start the retaining nut or bolt. Align fuel tank with the fuel tank support strap RH and fuel tank support strap LH.

     CAUTION: Ensure that fuel tank shields are installed with the fuel tank support strap RH and fuel tank support strap LH and are positioned correctly on the fuel tank . Refer to the applicable system illustration.

  1. Check the hoses and wiring mounted on the fuel tank top to ensure they are correctly routed and will not be pinched between the fuel tank and body.
  1. Tighten the fuel tank support strap retaining nuts or bolts to 29-41 Nm (22-30 lb-ft).
  1. Reconnect the fuel hoses and lines which were disconnected. Ensure that the fuel supply, fuel return (if present), and vapor vent connections are made correctly. Trace the various lines to the engine and refer to the applicable system illustrations to ensure the proper lines are connected.

    Install electric fuel pump (9350) as outlined.

  1. Connect electrical connections.
  1. Replace fuel drained from the fuel tank .
  1. Check all connections for leaks.