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. Place vehicle on hoist; do not raise.
2. Install Fuel Pressure Gauge T80L-9974-B and perform fuel pressure relief procedure.
3. Drain fuel tank.
4. Raise vehicle on hoist.
5. Disconnect and remove fuel filler hose.
6. Remove fuel tank as described and move electrical connector before moving fuel tank to bench.
7. Remove any dirt that has accumulated around the fuel tank sending unit retaining flange so that it will not enter the fuel tank during removal and installation.
8. Turn the fuel tank sending unit locking retainer ring counterclockwise using Fuel Tank Sender Wrench T74P-9275-A and remove locking ring.
9. Remove fuel pump and fuel level sensor from fuel tank.
10. Remove fuel level sensor gasket and discard.






INSTALLATION

1. Clean the fuel tank sending unit retaining flange, fuel tank mounting surface and fuel tank sending unit gasket groove.
2. Apply a light coating of Premium Long-Life Grease XG-1-C or XG-1-K or equivalent meeting Ford specification ESA-M1C75-B on a new fuel level sensor gasket to hold it in place during assembly and install in fuel tank sending unit gasket groove.
3. Install fuel pump and fuel level sensor carefully to make sure that the fuel filter element, hoses and float rod are not damaged or binding. Make sure locating keys are in keyways and fuel level sensor gasket remains in groove.
4. Hold fuel pump and fuel level sensor in place and install fuel tank sending unit locking retainer ring finger-tight. Make sure that all locking tabs are under fuel pump locking retainer ring.
5. Secure the fuel pump and fuel level sensor by rotating the fuel tank sending unit locking retainer ring clockwise using Fuel Tank Sender Wrench T74P-9275-A until fuel tank sending unit locking retainer ring stops against stops.
6. Move fuel tank from bench to vehicle.
7. Install fuel tank.
8. Lower vehicle.
9. Install a minimum of 38 L (10 gal) of fuel and check for leaks.
10. Install Fuel pressure Gauge T80L-9974-B on the fuel pressure relief valve. Turn ignition switch front OFF to ON position for three seconds. Turn ignition switch for three seconds repeatedly (5 to 10 times) until pressure gauge shows at least 241 kPa (35 psi). Check for leaks at fittings.
11. Remove Fuel Pressure Gauge T80L-9974-B, start engine and recheck for leaks.