Flexible Fuel Sensor: Service and Repair

Removal and Installation

WARNING: DO NOT MODIFY THE FLEXIBLE FUEL SYSTEM CONFIGURATION OR COMPONENTS, OR REPLACE COMPONENTS WITH PARTS NOT SPECIALLY DESIGNED FOR USE WITH FUEL METHANOL OR FUEL ETHANOL. FORD MOTOR COMPANY HAS SPECIALLY-DESIGNED THE MATERIALS, COMPONENTS AND SYSTEM CONFIGURATION FOR METHANOL-FUELED OR ETHANOL-FUELED VEHICLES AND EACH PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN FIRE, PERSONAL INJURY OR COULD CAUSE ENGINE DAMAGE.

1. Perform Fuel System Pre-Service Procedure and Fuel Pressure Release procedure.

2. Disconnect flexible fuel sensor electrical connector.

3. Raise vehicle on hoist.

4. Remove RH front tire and wheel assembly.

5. Remove fuel line retaining clip and fuel line from fuel mixer at inlet hose, using Fuel Line Disconnect Tool (3/8 inch) T90T-9550-C.


WARNING: COVER VALVE WITH SHOP CLOTH TO PREVENT ACCIDENTAL FUEL SPRAY INTO EYES.

6. Remove retainer and disconnect flexible fuel sensor outlet hose using Fuel Line Disconnect Tool (3/8 inch) T90T-9550-C.

7. Remove fuel supply and return hose from flexible fuel sensor bracket retaining clip and remove bracket to frame rail retaining bolts and flexible fuel sensor/mixer and bracket assembly from vehicle.

8. Loosen fuel mixer retainer clamp and disconnect fuel mixer outlet tube from flexible fuel sensor using Fuel Line Disconnect Tool (3/8 inch) T90T-9550-C.

9. Remove flexible fuel sensor retaining bolts and remove flexible fuel sensor from bracket.

10. To install, reverse Removal procedure.
- Tighten flexible fuel sensor-to-bracket bolts to 27-35 lb in 3-4 Nm).

- Tighten mixer retaining clamp to 51-82 lb in (5.8-9.3 Nm).

- Tighten flexible fuel sensor/mixer and bracket-to-frame bolts to 70-97 lb in (8-11 Nm).

- Tighten the wheel lug nuts to 85-104 lb ft (115-142 Nm).

11. Perform Fuel Charging System, Post-Service Procedures.