How to Change a Fuel Pump on a 1993 Ford Explorerby Jin MachinaUpdated November 07, 2017
Items you will need
Thick, heavy grease
The fuel pump to your 1993 Ford Explorer is designed to pressurize fuel that then travels through the fuel injectors and into the engine. A faulty fuel pump may be responsible for problems related to engine stalling and no-start conditions. Replacing the fuel pump is a procedure that can be done at home if you know how to remove the fuel tank and the fuel pump's fuel feed line and return lines, which are separate procedures that require separate tools. Other than acquiring the replacement parts, there are no special tools needed to perform this task on your own.
Removing the Fuel Pump
Relieve the fuel pressure system by disconnecting the electrical connector from the inertia shut-off switch, located on the passenger-side floor pan below the heater, and run the Explorer for several seconds until it stops.
Siphon the fuel tank until it is empty with a siphoning kit.
Remove the negative cable from the battery.
Jack the Explorer and support it, using jack stands.
Remove the fuel tank. This is a separate procedure.
Remove the fuel feed line and the return lines from the fuel pump module. This is a separate procedure.
Carefully knock loose the fuel-pump-module lock ring counterclockwise, using a brass punch and hammer.
Pull out the fuel pump from the fuel tank. Tilt the pump as you are doing this to prevent the fuel level float and sending unit from breaking off in the fuel tank.
Replace the O-ring seal on the tank if it is damaged.
Separate the electrical connector from the fuel pump. Use a small wrench to loosen the fuel hose lower clamp.
Separate the C-clip from the bottom of the fuel pump to remove the pump strainer using a flat-head screwdriver. If the strainer appears too contaminated to be cleaned with solvent, replace it.
Installing the New Fuel Pump
Wipe clean the fuel pump mounting area with a rag. Use thick grease for the new O-ring seal and place it around the opening on the fuel tank.
Attach the strainer to the new fuel pump and clip on the C-clip.
Install the new fuel pump to the fuel pump assembly by connecting the electrical connector to the fuel pump and tightening the clamp with a flat-head screwdriver.
Insert the fuel pump assembly into the fuel tank. Be careful not to damage the fuel level float and sending unit when installing the assembly.
Tighten the lock ring clockwise until the locking cams are underneath the retaining tangs. The new O-ring seal may make it difficult for it to lock, so you might have to push down while turning the lock ring.
Follow steps 6 to 3 of Section 1 in reverse order. Add gas to your Explorer. Follow Step 1 of Section 1 in reverse order to finish.
Fuel is extremely flammable. Do not smoke or work near open flames and sparks. Immediately wash off areas where fuel may have spilled on you.
Do not siphon the fuel tank by mouth.
- "Ford Explorer, Mazda Navajo, Mercury Mountaineer Automotive Repair Manual"; Jay Storer and John H. Haynes; 2001
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