How to Change the Fuel Pump on Ford Cars

by Contributing Writer; Updated June 12, 2017

The fuel pump to your Ford car is designed to pressurize fuel that then travels through the fuel injectors and into the engine. A faulty fuel pump may be responsible Ford car 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.

Under The Hood:

 How to Change the Fuel Pump on a '98 Taurus

Preparation

Siphon as much fuel out of the tank as possible with a vacuum pump and deposit it into a gas can.

Unplug the fuel pump inertia switch located behind the trim panel on the right side of the trunk. Start the engine and wait for it to stall.

Disconnect the negative battery cable in the engine compartment. Loosen the clamp nut for the battery's black cable with a wrench and remove the cable from the battery terminal.

Raise the car with its own floor jack and support it on jack stands, available from any auto parts store. Support the car on its rear end where the fuel cap and tank are located.

Removing the Tank

Open the gas cap door and remove the three bolts on the metal flange surrounding the filler neck (the pipe that you pump gasoline into) with a wrench.

Disconnect any metal braces between the filler tube and the car body and supporting the tube. Remove their bolts or screws with a wrench/screwdriver.

Disconnect the fuel and vapor line clamps with a screwdriver, then disconnect the fuel pump electrical connector and the connector to the emission shutoff valve.

Raise a floor jack under the fuel tank under the right rear corner of the car near the fuel cap. Place a block of wood large enough to cover the entire top part of the jack to protect the tank.

Unbolt the tank's support straps twrapped around the bottom of the tank with a wrench. Disconnect any other fuel lines and electrical connectors remaining on the top of the tank; press on their quick-connect fittings.

Removing the Pump

Tap the fuel pump assembly's locking ring counterclockwise with a wood rod or brass punch until it loosens.

Lift the long, curved fuel pump module out of the tank until you can reach its locking tabs, then squeeze the tabs together with your fingers and remove the fuel pump module from the tank. Pull off and discard the lock ring gasket from the top of the module.

Separate the fuel pump from the assembly by removing its clamp with pliers, disconnecting its electrical connector with pliers and removing its mounting screws. Use a Torx wrench to remove the screws.

Clean the fuel pump's mounting flange, tank mounting surface and seal ring groove with acetone or lacquer thinner and a clean rag.

Detach the strainer from the assembly by removing its C-clip with a small flat screwdriver. Wash the strainer with carburetor cleaner spray and reconnect it to the assembly. Clip the C-clip in place by hand.

Installation

Mount the replacement fuel pump in place on the module using its mounting screws and the Torx wrench, then plug in the electrical connector and connect the clamp by hand.

Align the fuel pump assembly with the retainer within the tank and push it into the retainer with your hands until the tabs click into place.

Install the pump assembly's sender plate by hand. Make sure the locating keys are in the keyways and the O-ring is in place.

Install a new seal ring on the fuel pump module by pushing it in place on the locking ring's underside; rub heavy grease on the seal ring to hold it in place. Insert the module into the hole in the tank and turn the locking ring clockwise to lock it in place.

Connect the fuel tank to the car in the reverse order of removal--raise it back into position with the floor jack, connect the fuel lines and electrical connectors strap it in place with the straps.

Lower the car and reconnect the battery cable. Connect the fuel pump inertia switch and press its reset button to energize the pump.

Items you will need

  • Siphon kit

  • Gas can

  • Jack

  • Jack stands

  • Screwdriver

  • Block of wood

  • Brass punch or wood rod

  • Wrench

  • Needle-nose pliers

  • Torx wrench

  • Carburetor cleaner spray

  • Acetone or lacquer thinner

  • Clean rags

  • Heavy grease

  • O-ring

 How to Change the Fuel Pump in a Ford Windstar

Relieve Fuel System Pressure

Loosen the fuel filler cap.

Disconnect the vacuum hose from the fuel pressure regulator with your hand. The regulator is located on the fuel rail leading to the fuel injectors, inside the engine compartment.

Connect a hand vacuum pump to the fuel pressure regulator and apply 25-inches Hg of vacuum to the regulator. Disconnect the vacuum pump from the regulator and re-connect the vacuum hose.

Remove as much fuel form the fuel tank through the filler neck into an approved container using a hand siphon pump.

Removing the Fuel Pump

Jack up the rear of the Windstar using a floor jack and support it on two jack stands.

Support the fuel tank with the floor jack and disconnect the tank straps using a ratchet, ratchet extension and socket.

Lower the fuel tank just enough to disconnect the fuel lines, vapor line and unplug the pump electrical connector from the fuel sending unit/pump assembly on top of the tank.

Lower the fuel tank and detach the sending unit/pump assembly using a lock ring removal tool. Turn the lock ring counterclockwise. See Resources below for more information.

Lift the sending unit/pump assembly from the tank and discard the seal gasket.

Remove the fuel pump from the assembly using a pair of slip joint pliers and standard screwdriver.

Installing the Fuel Pump

Mount the new pump on the sending unit/pump assembly using the slip joint pliers and standard screwdriver.

Apply a light coat of automotive grease to the new seal gasket to hold it in place and lay the gasket on the tank assembly opening.

Set the sending unit/pump assembly in place and turn the lock ring clockwise using the lock ring removal tool.

Raise the fuel tank with the floor jack just enough to connect the fuel lines, vapor line and plug the fuel pump electrical connector.

Set the fuel tank in place and connect the tank straps using the ratchet, ratchet extension and socket.

Lower the Ford Windstar.

Refill the fuel tank with at least 10 gallons of fuel.

Turn the ignition switch On for three seconds and then turn it Off. Repeat this operation at least 10 times to build pressure in the fuel system.

Check for leaks.

Items you will need

  • Hand-held vacuum pump

  • Fuel approved container

  • Hand siphon pump

  • Floor Jack

  • 2 jack stands

  • Ratchet and socket

  • Ratchet extension

  • Lock ring removal tool

  • Slip joint pliers

  • Standard screwdriver

  • New seal gasket

  • Automotive grease

 How to Change the Fuel Pump in a 2003 Ford Taurus

Find a flat surface in an area with plenty of ventilation. Since you will be working on the fuel line, and some fuel will inevitably spill, it is a good idea to do this outside or in a well-ventilated garage.

Back your car onto ramps, or lift it with a jack. If you are using a jack, make sure you are working on a hard, flat surface.

Relieve the fuel pressure. With your car still running, open the trunk and locate the inertia switch (emergency fuel shut-off). It is a little red button inside of your trunk.

Turn your ignition off (once the button is pushed, the engine will sputter and die).

Locate your fuel filter underneath the rear passenger door, attached to the frame.

Use your fingers or a screwdriver to remove the plastic clips from the fuel line going into each end of the filter.

Place the bucket or pan underneath the fuel filter.

Remove the fuel lines from each end of the fuel filter. Use a screwdriver to remove the bolt on the clamp holding the filter in place.

Place the filter into the clamp (paying attention to the flow lines on the new filter) and tighten the screw to secure the filter to the car frame.

Put the fuel line onto the filter and carefully fasten it with the new clips. Do not use your old clips--these will be brittle and can brake, causing your car to lose fuel.

Reset the inertia switch. It may take your car a few tries to start.

Items you will need

  • 2 tire ramps or a jack

  • Pan or bucket

  • Safety goggles

  • Flat screwdriver

 How to Change the Fuel Pump on a 1999 Ford Escort ZX2

Depressurizing the Fuel System

Open the Escort’s hood and find the battery junction box on the driver’s side of the engine compartment. Press the unlocking tab on the battery junction box lid and remove the lid.

Remove the fuel pump fuse, which is on the far right of the box, second fuse from the front.

Start the Escort and allow it to idle until it stalls, eliminating all pressure in the fuel system.

Removing and Installing the Fuel Pump

Loosen the pinch bolt on the negative battery cable end, using a combination wrench, and remove the negative battery cable from the battery. Position the cable aside to prevent accidental reconnection.

Look at the front of the rear seat cushion and find the two plastic tabs. Press these tabs toward the cushion to unlock it and lift the cushion to remove it. Set the cushion in a safe area away from your workspace.

Find the fuel pump access door, the metal panel with two wires running through it, in the floorboard where the seat cushion was. Disconnect the wiring harnesses on the two wires by prying upward on the locking tab on each harness with a small flat-head screwdriver and separating each harness from the ZX2’s harness.

Remove the four screws securing the fuel pump access panel with a Phillips screwdriver and remove the door. Press the rubber grommets and fuel pump wires through the holes in the access panel to free them.

Press the fuel line toward its inlet on the fuel pump and pry upward on the plastic clip securing the fuel line, using a small flat-head screwdriver, to remove it. Pull the fuel line from the fuel pump.

Use a fuel pump ring remover and a ratchet to remove the locking ring on the fuel pump. Pull the cap off the fuel pump module.

Find the two small plastic locking tabs securing the fuel pump assembly. Squeeze the locking tabs together and pull the fuel pump module from the tank. Remove the old O-ring, if it stayed on the gas tank, with a hooked O-ring puller.

Guide the new fuel pump into the tank and press it downward until you hear the tabs click into place.

Press the new O-ring, which comes with the new fuel pump, into its groove on the underside of the fuel pump cap. Lower the fuel pump cap onto the fuel pump and hand-thread the locking ring. Tighten the locking ring with a fuel pump ring remover and a ratchet. Tighten the ring only until it is snug, as you do not want to bend the fuel pump cap.

Press the fuel line into its inlet on the top of the fuel pump and press a new plastic clip, which comes with a new fuel pump, into the slot on the end of the fuel line to lock it into place. Tug the fuel line lightly to assure it is locked in place.

Guide the fuel pump wires through their holes in the access door and press the grommets on the wires into the holes in the door until they seat into place. Set the access door back into place on the floorboard and tighten its retaining screws with a Phillips screwdriver.

Reconnect the negative battery cable and tighten the cable end’s pinch bolt to 6 foot-pounds with a torque wrench and socket.

Press the rear of the seat cushion under the rear seat-back cushion, making certain the seat belts do not get trapped under the seat cushion. Press the front of the cushion downward to lock it into place.

Pressurizing the Fuel System

Reinstall the fuel pump fuse into its receptacle in the battery junction box. Close the battery junction box’s lid.

Turn the ignition to the “Run” position and leave it there for about five seconds. Turn the ignition to the “Off” position. Repeat this step two times.

Start the engine and verify that it starts. If it does not start, recheck the installation of the fuel pump.

Items you will need

  • Combination wrench set

  • Small flat-head screwdriver

  • Phillips screwdriver

  • Hooked O-ring puller

  • Fuel pump ring remover

  • Torque wrench

  • Socket set

 How to Change the Fuel Pump in a 2002 Ford Escape

Relieve Fuel-System Pressure

Remove the fuel-pump relay form the relay center (if you have a 2.0L engine model). The relay center is on the driver side of the engine compartment. If you have a 3.0L engine model, go to step 3.

Shift the transmission to neutral, start the engine and let it idle until it stalls. Then, crank the engine for about 3 seconds and turn off the ignition switch. Go to Section 2, Step 1.

Locate the Schrader valve at the end of the fuel rail around the top of the engine. This valve resembles an air valve on a bicycle tire.

Remove the valve cap.

Wrap a shop rag around the valve.

Depress the valve with a small screwdriver and catch the squirt of fuel with the shop rag. Now replace the valve cap.

Remove the Fuel Pump

Disconnect the black (negative) battery cable using a wrench.

Loosen the fuel filler cap.

Raise the left-rear seat cushion.

Lift the floor carpet.

Unscrew the FPM's access cover located on the floor using a Phillips screwdriver or ratchet and socket. Now remove the access cover.

Unplug the FPM's electrical connectors.

Detach the fuel and vapor lines from the FPM. Depending on your vehicle model, you might need a fuel-pipe remover tool (see the resources box at the bottom). Otherwise, just squeeze the lock tabs on the line fittings and pull the lines from the fitting to disconnect them.

Detach the FPM from the fuel tank using a fuel sender wrench (see the resources box at the bottom).

Lift the FPM from the fuel tank and the module O-ring. Now remove the fuel pump from the module.

Install the New Fuel Pump

Install the new fuel pump on the FPM and set the module on the fuel tank along with a new O-ring.

Attach the FPM to the fuel tank using the fuel sender wrench.

Connect the fuel and vapor lines to the fittings on the FPM.

Plug the FPM's electrical connectors.

Screw on the FPM's access cover using the Phillips screwdriver or ratchet and socket.

Replace the floor carpet.

Lower the left-rear seat cushion.

Tighten the fuel filler cap.

Connect the black (negative) battery cable using the wrench.

Items you will need

  • Shop Rag

  • Small Screwdriver (if necessary)

  • Wrench

  • Phillips Screwdriver or Ratchet and Socket

  • Fuel-Pipe Remover Tool (if necessary)

  • Fuel Sender Wrench

  • New O-ring

 How to Change a Fuel Pump in a Ford Crown Victoria

Park the vehicle in a safe place and make sure there is enough room around the back of the vehicle for you to work and move tools around.

Start the engine and let it idle while you relieve the fuel system pressure by removing the fuel pump fuse or relay from the fuse box. Wait a few seconds for the engine to stall, turn the ignition key off and replace the relay or fuse.

Raise the back of your car using a floor jack and support it safely on jack stands.

Disconnect the fuel tank filler pipe and the fuel pump connector located above the cross member underneath the vehicle.

Disconnect the vapor tube from the tee connector on the right side of the car-passenger side-and the vapor line from the canister tube.

Support the fuel tank with a jack and remove the nuts from the holding strap using a wrench or ratchet and socket. Move the strap away and lower the fuel tank. Discard the fuel tank mounting studs.

Unplug the pressure transducer electrical connector located on the top rear corner of the fuel tank.

Clean the area around the fuel pump mounting flange and remove the flange mounting bolts in a crisscross pattern.

Lift the fuel pump assembly off the tank. Replace the new fuel pump in the assembly and install the assembly in the tank. Install the flange screws and torque to 89 inch lbs. (10Nm) using a crisscross pattern.

Raise the fuel tank to its mounting position, install the strap using new mounting studs and torque the nuts to 26 foot lbs. (35 Nm).

Connect the fuel pressure transducer electrical connector, vapor tube to the tee connector, vapor line to the canister tube, fuel tank filler pipe and fuel pump electrical connector.

Lower the vehicle, start the engine and check for leaks.

Items you will need

  • Floor jack and 2 jack stands

  • Wrench set

  • Ratchet and socket set

  • New fuel tank mounting studs

 How to Change a Fuel Pump on a 2002 Ford Taurus

Relieving the Fuel System Pressure

Park your Taurus in a well-ventilated area with a level surface and away from appliances with open flames such as dryers and water heaters.

Open the hood and remove the fuel pump relay from the fuse box.

Start the engine and allow it to idle until it stalls.

Crank the engine for five seconds to finish relieving the fuel system pressure.

Turn the ignition key to the "Off" position.

Disconnect the negative (black) battery cable using a wrench.

Removing the Fuel Pump

Remove the fuel tank filler cap.

Drain the fuel from the fuel tank, if necessary, down to 1/4 tank or less. Use a hand siphon pump and a suitable container.

Raise the rear of your Taurus using a floor jack and support it on two jack stands.

Chock the front wheels.

Disconnect the three quick-connect couplings from the tubes at the tank by hand. If necessary, label each connector for easy reassembly.

Unplug the fuel pump electrical connector.

Disconnect the fuel filter inlet tube from the filter by hand.

Support the fuel tank with the floor jack. Place a wooden block between the tank and floor jack to prevent damage to the tank.

Unfasten the two fuel tank support straps using a ratchet, ratchet extension and socket.

Carefully lower the fuel tank.

Clean the top of the fuel pump module using a wire brush and rag to prevent dirt and debris from falling into the fuel tank after you remove the pump module.

Unscrew the fuel pump module retaining ring using tool number 310-D006 or a suitable retaining ring remover.

Turn the fuel pump module counterclockwise by hand to disengage the module from its mounting flange. Then, carefully lift and remove the module from the tank. Discard the fuel pump module sealer.

Installing the Fuel Pump

Remove the old fuel pump from the module using slip joint pliers and a screwdriver.

Install the new fuel pump on the module using the slip joint pliers and screwdriver.

Install a new fuel pump module sealer and carefully insert the fuel pump module in the tank.

Turn the fuel pump module clockwise until it hits the stops at the mounting flange.

Screw in the fuel pump module retaining ring using tool number 310-D006 or a suitable retaining ring remover.

Carefully lift the fuel tank into position.

Fasten the two fuel tank support straps using the ratchet, ratchet extension and socket.

Remove the floor jack from under the vehicle.

Connect the fuel filter inlet tube to the filter by hand.

Plug in the fuel pump electrical connector.

Connect the three quick connect couplings to the tubes at the tank.

Lower the vehicle.

Remove the chokes from the front wheels.

Refill the fuel tank, replace the fuel filler cap and fuel pump relay.

Connect the negative (black) battery cable using the wrench.

Turn the ignition key to the "On" position to pressurize the fuel system.

Check for leaks at the fuel tank.

Turn off the ignition key.

Items you will need

  • Wrench

  • Hand siphon pump, if necessary

  • Fuel container, if necessary

  • Floor jack

  • 2 jack stands

  • 2 chocks

  • Ratchet

  • Ratchet extension

  • Socket

  • Wire brush

  • Rag

  • Special tool 310-D006 or equivalent

  • Slip joint pliers

  • Standard screwdriver

  • New fuel pump module sealer

 How to Change a Fuel Pump on a Ford Escort

Jack up the rear of your Escort, and place the car on jack stands.

Open the hood and disconnect the vehicle's battery.

Loosen the connection of the cold start valve at the top of the fuel distributor, using a small wrench. Use a rag to absorb any fuel that may drain from this valve. You may need to loosen the connection of the fuel feed line where it runs into the warm-up regulator if you have the K-Jetronic system. You can loosen the feed line with a small wrench, using a rag to soak up any spilled fuel.

Clamp the fuel inlet hose with line clamps, vise grips or something similar. Be sure this fuel line is clamped well to prevent fuel spillage.

Disconnect the inlet and outlet lines from the fuel pump, using a small wrench. You may want a container under the lines to catch fuel spillage. Cover the ends of the lines or tape them off temporarily to ensure that no dirt or dust enters the fuel system while the lines are exposed.

Disconnect the electrical connections on the fuel pump. Loosen the bolt on the retaining bracket holding the fuel pump in place, and slide the fuel pump out. Place it in the container you used to catch fuel spillage if you want to contain all the fuel in one place for easy cleanup.

Position your new fuel pump in place where you removed the old one. Be sure the rubber sleeve around the pump is properly in place to protect the pump. Tighten the bolt on the retaining bracket to hold the pump in place while you complete reassembly.

Reconnect the electrical feed, inlet and outlet lines. Remove the clamp from the fuel inlet hose once it is securely reconnected to the pump. Tighten the cold start valve at the fuel distributor or the fuel feed line at the warm-up regulator.

Lower the car and reconnect the battery. Start the Escort and check it for any fuel leaks.

Items you will need

  • Jack

  • Jack stands

  • Metric and SAE wrenches

  • Rags

  • Small hose clamps or vise grips

  • Bucket or other container

  • Fuel pump

 How to Change a Fuel Pump on a 1993 Ford Explorer

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.

Items you will need

  • Safety glasses

  • Mechanic's gloves

  • Siphoning kit

  • Jack

  • Jack stands

  • Brass punch

  • Hammer

  • O-ring seal

  • Wrench set

  • Flat-head screwdriver

  • Thick, heavy grease

 How to Replace a Fuel Pump on a 1998 Ford Explorer

Empty the gas tank using a fuel siphoning kit. Store the gas in an EPA-approved container.

Relieve the fuel pressure by removing the fuel pump relay from the fuse box under the hood and starting the vehicle. The engine will run for a few seconds and shut off after burning the remaining gas in the fuel line.

Disconnect the negative cable from the battery terminal. Raise the vehicle using a jack and secure it with jack stands.

Disconnect the fuel filler neck and vent hose by removing the clamps. Remove the ground strap. Disconnect the fuel pump electrical connector.

Support the fuel tank using a jack. Remove the rear retaining bracket. Slide the fuel tank toward the rear of the vehicle to remove it from the front bracket.

Remove the fuel lines using the disconnect tool. Remove the fuel pump bolts and slide the fuel pump out of the tank. Disconnect the remaining electrical connector and remove the fuel pump from the work area.

Install the new fuel pump and assemble the fuel tank. Reinstall the fuel tank and connect the fuel lines. Remove the jack stands and lower the vehicle. Connect the battery and reinstall the fuel pump relay.

Items you will need

  • Fuel line disconnect tool

  • Fuel siphoning kit

  • Jack

  • Jack stands

  • Socket set

  • Socket wrench

  • Screwdriver

 How to Replace the Fuel Pump On a 7.3 Diesel

Disconnect the negative battery cable from the battery with a socket.

Relieve the fuel line pressure by removing the fuel filler cap.

Remove the banjo bolt that secures the hard gas lines to the front of the pump. Use a socket to remove the bolt. Some diesel will come out of the pump when you remove the bolt. Have a catch can ready to catch the fuel.

Remove the three hose clamps that secure the hoses to the rear of the pump with a pair of pliers. Pull the hoses off the pump.

Remove the two bolts that hold the pump to the frame using a socket. Discard the old pump.

Place the new pump on the frame rail and secure it with the two bolts and the socket.

Push the three hoses onto the back of the pump and secure them using the clamps and pliers.

Secure the banjo bolt to the front of the new pump with the socket and ratchet.

Reconnect the negative battery cable to the negative battery terminal with the socket and ratchet.

Items you will need

  • Socket set

  • Catch can

  • Pliers

 How to Replace a Fuel Pump on a 2000 Ford Expedition

Removal

Park the vehicle on a level surface and turn off the ignition. Raise and secure the vehicle's hood. Disconnect the negative battery cable with a wrench. Connect a fuel pressure gauge onto the pressure test port; this is located on the fuel rail near the center of the engine compartment. Turn the valve to bleed the fuel into a metal cup or other gas-safe container, relieving the fuel pressure.

Raise the truck's rear end with a jack and support it on jack stands. If there is a skid plate covering the gas tank, which is located behind the truck's fuel filler door, unbolt it with a wrench and remove it.

Disconnect the fill/vapor hoses from the tank neck, loosening the clamps with a screwdriver. Disconnect the fuel/EVAP lines at the quick-connect fittings and disconnect the pump electrical connector with a flat-head screwdriver, which are on or near the fuel pump flange.

Raise the floor jack with a block of wood on it under the tank to support it. Unbolt the tank straps, lower the jack and disconnect any remaining wire harnesses or lines by pressing the quick-connect fittings.

Highlight with a marker the alignment mark on the fuel tank that lines up with the mark on the fuel pump flange.

Remove the six bolts fastening the fuel pump module to the tank, using a small flare-nut wrench, and lift the module out of the tank.

Disconnect the electrical connector--the small two-part plug device underneath the pump--from the pump/sending unit assembly; use a small screwdriver if you cannot do it by hand. Remove the clamp's bolt with a small wrench to remove the pump from the assembly.

Installation

Install the fuel pump to the assembly with its clamp and electrical connector.

Lower the assembly into the tank, making sure you do not damage the new pump's strainer, and apply the mounting bolts. Make sure the alignment mark on the flange lines up with the one on the tank.

Raise the tank into position and secure it to the vehicle with its straps and strap bolts. Reconnect the fuel lines, electrical connectors and the fill/vapor hoses.

Reconnect the skid plate with its bolts, if applicable.

Lower the truck off the jack stands with the jack.

Items you will need

  • Fuel-pressure gauge

  • Gasoline-safe container

  • Floor jack

  • Jack stands

  • Wood block

  • Wrenches

  • Screwdrivers

  • Marker

 How to Replace the Fuel Pump on the Ford Contour

Disconnect the negative battery cable from its terminal for safety. Unscrew the bolt that holds it on the terminal with the pliers.

Open the fuel tank fill cap to release any pressure still in the tank.

Open the hood of the car, and find the pressure relief valve located at the fuel rail.

Connect the fuel pressure gauge to the pressure relief valve.

Release any pressure trapped in the system by pressing the pressure relief valve on the gauge.

Open the manual valve on the gauge to drain any remaining fuel in the system into the empty gas container.

Remove the pressure gauge from the system, and return the fuel tank fill cap.

Remove the rear seats, using the 3/8-inch ratchet.

Remove the rubber cap on the floor pan to expose the top of the fuel pump.

Disconnect all electrical harness connectors on the fuel pump.

Press both tabs of the nylon push connect fitting to remove all the fuel lines connected to the fuel pump.

Remove the fuel pump, using the sender wrench to turn the fuel pump locking ring counterclockwise. (If the sender wrench is unavailable, use a hammer and a drift punch)

Remove the old fuel pump O-ring and replace it with the new O-ring that has been lightly dabbed with grease.

Install the new fuel pump, and return the fuel pump locking ring.

Tighten the fuel pump locking ring by turning the sender wrench clockwise. (If the sender wrench is unavailable, use a hammer and a drift punch)

Reconnect all the fuel lines and all the electrical harness connectors to the fuel pump.

Reinstall the rubber cap on the floor pan, and install the rear seats.

Reconnect the negative battery cable to its terminal.

Items you will need

  • Pliers

  • Ford Contour fuel pump

  • Fuel pump O-ring

  • Sender wrench D84P-9275-A (if unavailable, a hammer and a drift punch will also do the job)

  • Fuel pressure gauge

  • 3/8-inch ratchet and a set of sockets

  • Empty gas container

 How to Replace a Fuel Pump in a Ford F-150

Relieve the Fuel System Pressure

Detach the splash shield from the frame rail located underneath the driver's side door. Use a ratchet and socket.

Unplug the electrical connector you will see after removing the splash shield. The connector leads to the fuel pump module.

Start the engine and let it idle until it stalls. Then crank the engine for about five seconds to relieve the remaining fuel pressure from the system. If the engine does not start due to a bad fuel pump, crank the engine to make sure fuel pressure is relieved.

Turn the ignition key to the "Off" position.

Remove the Fuel Pump

Disconnect the ground battery cable from the battery using a wrench.

Jack up the rear of your F-150 using a floor jack and support it on two jack stands.

Remove the tank shield if your particular model is equipped with it using a ratchet, ratchet extension and socket.

Support the fuel tank with the floor jack.

Disconnect the straps holding the tank to the truck's body using the ratchet, ratchet extension and socket.

Lower the fuel tank just enough to gain access to the fuel lines, vapor lines and fuel pump electrical connector on top of the tank.

Disconnect the fuel lines and vapor lines from the sending unit/pump module. Press the lock tabs on the lines' quick connectors and carefully pull the lines from their fittings. Unplug the pump-module electrical connector.

Release the sending unit/pump module by turning the lock ring counterclockwise using the fuel tank sending unit wrench 310-123 or equivalent (see Resources and Tips for more information).

Lift the sending unit/pump module off the tank carefully and discard the O-ring seal underneath the flange of the module.

Install the Fuel Pump

Remove the old fuel pump from the module using a screwdriver and a pair of slip joint pliers and install the new pump on the module.

Lubricate the new O-ring seal with clean engine oil and lay the seal on the fuel tank opening.

Install the sending unit/pump module in the tank and turn the lock ring clockwise using the fuel tank sending unit wrench.

Lift the fuel tank just enough to attach the fuel lines and vapor line and plug the pump module electrical connector.

Raise the fuel tank to set it in its mounting place and secure the tank straps using the ratchet, ratchet extension and socket.

Install the fuel tank shield using the ratchet, ratchet extension and socket, if you had to remove it.

Lower your F-150.

Connect the ground, battery cable using the wrench.

Build Fuel System Pressure

Plug the electrical connector located on the frame rail underneath the driver's side door.

Attach the splash shield to the frame rail using the ratchet and socket.

Turn the ignition key to the "On" position for three seconds to let the fuel system build pressure. Then turn the key to the "Off" position. Repeat the cycle three times to make sure the system has enough pressure.

Start the engine and check for fuel leaks.

Items you will need

  • Ratchet and socket

  • Wrench set

  • Floor jack and 2 jack stands

  • Ratchet extension

  • Fuel tank sending unit wrench number 310-123

  • Screwdriver

  • Slip joint pliers

  • New O-ring seal

  • Clean engine oil

 How to Replace the Fuel Pump in a Ford Expedition

Open the hood and disconnect the negative battery cable using the battery wrench. Push the cable end over so it cannot contact the battery terminal during the rest of the procedure.

Roll the floor jack under the rear of the Expedition and center it under the gas tank. Lift the jack head up until it touches the bottom of the tank.

Unbolt the gas tank retaining straps using the socket set. Lower the tank several inches until you can reach your arm between the tank and the bottom of the Expedition.

Disconnect the fuel pump wiring and fuel lines from the fuel pump by hand. The pump is in the top-center of the gas tank. Disconnect the fuel filler neck from the tank also using the screwdriver.

Lower the gas tank down using the floor jack, making sure to keep it level. Roll the tank out from under the Expedition and set it on the ground.

Wrap the rag around the tip of the screwdriver, place the tip against the fuel pump retaining ring and tap the handle of the screwdriver with the rubber mallet until the retaining ring turns loose. You’ll want to turn the ring counterclockwise.

Lift the old fuel pump up and out of the gas tank. Lower the new pump down into the tank, making sure to position the fuel level float in such a way that it does not contact the side of the tank. Tighten the retaining ring in reverse of how you removed it.

Place the gas tank back onto the floor jack, roll it back under the Expedition and then raise it back into position. Reconnect the fuel pump wiring harness, fuel lines and fuel filler neck before raising the tank to the full height.

Bolt the gas tank retaining straps back into position with the socket set. Roll the floor jack out from under the Expedition and then reconnect the negative battery cable to the battery.

Items you will need

  • Battery wrench

  • Floor jack

  • Socket set

  • Rag

  • Screwdriver

  • Rubber mallet