Fuel Pump: Service and Repair

WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury.

CAUTION: Fuel supply lines will remain pressurized for long periods of time after engine shut down. This pressure must be relieved before servicing of the fuel system is begun. A valve is provided on the throttle body for this purpose. Remove the air cleaner and relieve system pressure by using Rotunda pressure gauge tool T80L-9974-A or equivalent and drain the system through the drain tube.

REMOVAL

1. Perform the fuel pressure release procedure.
2. Remove rear seat cushion.
3. Remove plastic grommet from floor pan.
4. Disconnect fuel pump module electrical connector.
5. Disconnect fuel and vapor return tubes from fuel pump module by compressing tabs on both sides of each nylon push connect fitting and easing the fuel line out of fuel pump module.
6. Turn fuel pump locking retainer ring counterclockwise using fuel tank sender wrench and remove fuel pump locking retainer ring.
7. Remove fuel pump module and cover fuel pump module opening in fuel tank.

NOTE: After fuel pump module removal, immediately cover fuel pump module opening in fuel tank in order to prevent fuel system contamination.

8. Remove fuel pump module O-ring seal and discard.

INSTALLATION

1. Clean fuel pump module mounting flange and fuel pump module mounting surface and O-ring seal groove on fuel tank.

NOTE: When cleaning fuel pump module mounting surface on fuel tank, use caution to prevent any foreign material from entering fuel system.

2. Apply a light coat of Premium Long-Life Grease meeting Ford specification ESA-M1C75-B on a new O-ring seal to hold it in place and install it into the O-ring seal groove on the fuel tank.
3. Install fuel pump module carefully to ensure that filter is not damaged. Ensure that locating keys are in keyways and O-ring seal remains in place.
4. Hold fuel pump module in place and install fuel pump locking retainer ring finger-tight. Ensure that all locking tabs are under fuel tank lock ring tabs.
5. Secure fuel pump locking retainer ring by rotating clockwise using fuel tank sender wrench until fuel pump locking retainer ring rests against stops.
6. Connect fuel and vapor return tubes to fuel pump module.
7. Connect fuel pump module electrical connector.
8. Install plastic grommet in floor pan.
9. Install rear seat cushion.
10. Install fuel pressure gauge.
11. Turn ignition switch to RUN position for three seconds repeatedly (5 to 10 times) until pressure gauge reads at least 270 kPa (30 psi). Check for leaks at fittings.
12. Remove pressure gauge, start engine and recheck for leaks.