Fuel Pump: Service and Repair

REMOVAL

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.

1. Place vehicle on hoist but do not raise.
2. Install Multiport Fuel Injection (MFI) Fuel Pressure Gauge T80L-9974-B and depressurize fuel system.
3. Drain Fuel from fuel tank through fuel tank filler pipe.
4. Raise vehicle on hoist.
5. Remove Fuel Tank and move to bench.
6. Remove any dirt that has accumulated around fuel pump module retaining flange so that it will not enter fuel tank during removal and installation.
7. Turn fuel pump locking retainer ring counterclockwise using Fuel Tank Sender Wrench T74P-9275-A and remove fuel pump locking retainer ring.
8. Pull fuel pump module sender plate up out of tank until locking tabs for module are accessible. Squeeze both locking tabs together and remove fuel pump module from fuel tank.
9. Remove O-ring seal and discard.

INSTALLATION

Fuel Pump Module Terminals:

1. Clean the fuel pump module mounting 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 it in seal ring groove.
3. Install the fuel pump module carefully into the fuel tank to make sure that the filter, hoses and float rod are not damaged or binding. Align the fuel pump module and the fuel tank retainer axially and push the fuel pump module into the fuel tank retainer. When the fuel pump module is engaged, a definite click will be heard and the (two) outside tabs on the fuel pump module will be engaged on the outside of the fuel tank retainer. The fuel pump module must be snapped in the retainer with both tabs. Pull on the fuel pump module to make sure it is fully engaged. Install 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 locking retainer ring finger-tight. Make sure that all locking tabs are under fuel pump locking retainer ring tabs.
5. Secure the fuel pump module unit by rotating the fuel pump locking retainer ring clockwise using Fuel Tank Sender Wrench T74P-9275-A until fuel pump locking retainer ring stops against stops.
6. Move fuel tank from bench to vehicle.
7. Install Fuel Tank in vehicle.
8. Lower vehicle.
9. Install a minimum of 38 liters (10 gallons) of fuel. Check for leaks.
10. Turn ignition switch to RUN position for three seconds repeatedly (5 to 10 times) until Multiport Fuel Injection (MFI) Fuel Pressure Gauge T80L-9974-B shows at least 207 kPa (30 psi). Check for leaks at fittings.
11. Remove MFI Fuel Pressure Gauge T80L-9974-B, start engine and recheck for leaks.