Fuel Pump: Service and Repair

Fuel Pressure Gauge:

SPECIAL TOOL(S) REQUIRED

Quick Connect/Disconnect Tool:

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. Remove fuel tank.
2. Remove any dirt that has accumulated around the fuel pump module retaining flange.
3. Remove the bolts which retain the fuel pump sender plate to the fuel tank.
4. Pull fuel pump module sender plate up out of fuel tank until locking tabs for fuel pump module are accessible. Reach through the fuel pump 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-B 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 the retainer. A definite click will be heard when the tabs on fuel pump module engage the fuel tank retainer. Make sure the fuel pump is snapped in the retainer with both tabs. Pull on fuel pump module to make sure it is fully engaged.
4. Install fuel pump sender plate. Tighten retaining bolts to 9-12 Nm (80-106 lb-in).
5. Install fuel tank in vehicle.
6. Lower vehicle.
7. Install a minimum of 38 liters (10 gallons) of fuel. Check for leaks.
8. Turn ignition switch to RUN position for three seconds repeatedly (5 to 10 times) until Fuel Pressure Gauge 310-012 (T80L-9974-B) shows at least 207 kPa (30 psi). Check for leaks at fittings.
9. Remove fuel pressure gauge, start engine, and recheck for leaks.