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.

SPECIAL SERVICE TOOL(S) REQUIRED

Description
- Fuel Tank Sender wrench
- Multiport Fuel Injection (MFI) Fuel Pressure Gauge

Tool Number
- 310-002 (T74P-9275-A)
- 310-012 (T80L-9974-B)






REMOVAL

1. Remove fuel tank.
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.
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 Rotunda Fuel (Methanol/Ethanol) Pressure Test Kit 134-R0131 or equivalent (depending upon application) shows at least 207 kPa (30 psi). Check for leaks at fittings.
10. Remove Test Kit, start engine, and recheck for leaks.