How to Install a Fuel Pump on Ford Cars

by Contributing Writer

The Ford car is a popular small pickup truck that has survived the test of time. Many people have chosen to own this truck Ford car it's advantages in fuel economy over the larger trucks out there. Doing your own repair work is not only more cost efficient but can be empowering. Everyone enjoys the accomplishments of fixing things on there own. Do you have basic mechanic's tools, basic mechanical knowledge? Then you can do it yourself. Get ready to be your own mechanic with these step on how to repair the fuel pump in a Ford car.

Under The Hood:

 How to Install a Fuel Pump on a 2002 Explorer

Relieve the residual fuel pressure in the fuel lines by removing the 20-amp fuel pump fuse located in position 19 (marked on the fuse block) in the under-hood fuse block of the 2002 Explorer. Start the engine and allow it to run until it stalls indicating the fuel pressure is relieved. Turn the key to the "Off" position.

Push wheel chocks in front of, and behind, the front wheels. Lift the rear of the Explorer using a floor jack under the center of the differential and slide jack stands under both rear axle tubes. Lower the truck onto the stands, to support the vehicle's weight, for safety.

Unplug the electrical connector located near the front of the fuel tank by lifting the locking tab as you pull the two halves of the connector apart. Disconnect the fuel filler neck and vent hose from the fuel tank by loosening the hose clamps on the hoses using a screwdriver and then prying the hoses off the fuel tank.

Roll the floor jack under the fuel tank and place a wood block between the jack and the tank. Lift the tank up slightly and remove the 15-mm bolts that attach the tank straps to the frame of the car. Lower the tank down with the floor jack until you can reach the fuel lines on top of the tank.

Disconnect the fuel lines by disconnecting the the quick disconnect fittings using the fuel line disconnect tool. In the 2002 Explorer the fittings are located on the top of the fuel tank attached to the fuel pump assembly. Clip the tool around the metal portion of the line and push it into the fitting then pull the two halves of the line apart.

Lower the tank and slide it from under the Explorer. Rotate the lock ring that secures the fuel pump assembly to the tank using a screw driver and hammer until the spring loaded assembly pops up from the tank. Lift the assembly from the tank.

Slip the new fuel pump assembly into the tanks and secure it in place with the locking ring. Slide the tank under the vehicle and lift it into place using the floor jack and block of wood. Reconnect the fuel lines by pushing them onto the fuel pump assembly until they click into place and can not be pulled off without the disconnect tool.

Reinstall the tank straps, fuel filler neck, vent hose and electrical connector. Reinstall the fuel pump fuse into the fuse block. Turn the ignition key to the "RUN" position for two seconds and then turn it to the "Off" position. Cycle the ignition key in this manner several times to prime the fuel system. Start the engine and check for leaks.

Lift the Explorer off the jack stands using the floor jack. Remove the stands and lower the vehicle to the ground. Remove the wheel chocks and test drive the Explorer to verify it runs properly.

Items you will need

  • Wheel chocks

  • Floor jack

  • Jack stands

  • Socket set

  • Fuel line disconnect tool

  • Hammer

  • Screwdriver set

 How to Install a Fuel Pump on a 1994 Ford Ranger

How to Install a Fuel Pump on a 1994 Ford Ranger

Relieve the pressure on the fuel system by removing the fuel pump fuse. Allow the truck to cut off on it's own. Crank engine 2 to 3 times to make sure pressure is relieved. Disconnect the negative battery cable at this point.

Remove the gas tank. The fuel Pump is inside the Fuel Tank. If the fuel tank still has gas in it you will want to remove it you can purchase a siphon kit from you local auto parts store. (warning: never siphon gas by mouth). Raise the rear of the vehicle and place it securely on the jack stands. Remove the heat shield, skid plate and front retaining strap. Using the jack support the fuel tank. Position the piece of wood between the jack head and the tank to protect the tank. Remove the rear retaining strap. Loosen the clamp on the fill pipe and the vent pipe and remove at the tank. Lower tank just enough to unhook the vapor valve and fuel line connectors from the sending unit and vapor valve. Disconnect the fuel pump and fuel gauge sending unit connectors at rear of tank. Gas tank should now hinge down. Remove tank from vehicle.

Remove any dirt that has built up where the fuel sender/pump is attached and don't allow work to get into tank.

Remove Lock Ring, turn counterclockwise with lock ring wrench or flathead screwdriver until loosened. Remove lock ring.

Remove the pump/sending unit from the tank. This will need a bit of manipulation on your part, and be careful not to bend the arm of the sending float.

Remove old lock ring seal and trash it.

Clean fuel pump mounting flange, tank mounting surface and seal ring groove.

Installation is done in reveres with these added steps. Apply thin coat of grease to new lock ring seal. (this is to help hold it in place during assembly) Put the seal in the lock ring groove. Install the pump into the fuel tank so that the tabs of the unit are positioned into the slots in the fuel tank. (be sure the seal is kept in place until the lock ring has been tightened.) Hold the fuel pump in place, install and tighten the locking ring clockwise.

Items you will need

  • New Fuel Pump and Lock Ring Seal

  • Metric ratchet and socket set

  • Ratchet extensions (may need)

  • Jack and Jack Stands

  • Philips and Flathead Screwdriver

  • Pliers

  • Small piece of plywood

  • Wheel Chucks (something to block front wheels)

  • Lock Ring Wrench (optional)

 How to Install a Fuel Pump on Ford 390

Loosen the clamp on the tip of the negative battery cable with wrench, then pull the cable off of the battery.

Disconnect the rubber inlet line from the bottom of the fuel pump. The inlet line fits onto a metal nipple on the pump, and is secured with a single clamp. Loosen the clamp with either a nut driver or flathead screwdriver, then pull the line off of the pump. Insert the tip of the line into a plastic bag, as a small amount of gasoline will likely drip from the line.

Disconnect the metal outlet line from the bottom of the fuel pump. The outline line features an in-line nut at its tip, which screws into the fuel pump. Turn the nut in a counterclockwise direction with a wrench until the tip disconnects from the pump. Insert the tip of the line into a plastic bag, as a small amount of gasoline will likely drip from the line.

Remove the two bolts located on either side of the fuel pump with a socket wrench, then pull the pump off of the engine.

Wipe down the opening on the side of the engine that the fuel pump bolts to with a rag and engine degreaser. It is important that any old gasket material be removed from this surface so that the new fuel pump gasket will adhere to the engine properly.

Apply gasket sealant to one side of a new fuel pump gasket, then press the gasket into place on the engine.

Apply gasket sealant to the remaining side of the new fuel pump gasket.

Press the replacement fuel pump against the gasket, then install the pump's two retaining bolts with a socket wrench.

Tighten the in-line nut at the tip of the metal outlet line onto the bottom of the fuel pump.

Press the tip of the rubber inlet line onto the metal nipple on the bottom of the fuel pump, then tighten the line's clamp until the line is secure.

Reattach the negative battery cable to the battery by tightening the nut at the tip of the cable with a wrench.

Items you will need

  • Wrench

  • Nut driver or flathead screwdriver

  • Plastic bags (2)

  • Socket wrench

  • Rag

  • Engine degreaser

  • Gasket sealant

  • Fuel pump gasket

 How to Install a Fuel Pump on a Ford Escape

Relieve the Fuel System Pressure on a 2.0L Engine

Open the hood and remove the relay panel cover inside the engine compartment.

Look for the fuel pump relay. The marks inside the panel cover will indicate the correct relay.

Remove the fuel pump relay.

Start the engine. The lack of fuel will stall the engine and relieve the fuel system pressure.

Replace the fuel pump relay and turn off the ignition switch. Then go to the next section.

Relieve the Fuel System Pressure on All Other Models

Locate the Schrader valve at the end of the fuel rail where the fuel injectors attach. The valve will most likely have a small plastic cap that looks like the air valve on your vehicle's tires.

Remove the valve cap and connect a fuel pressure gauge equipped with a drain line.

Insert the drain line into an empty container to drain the fuel.

Open the valve on the fuel gauge and drain the fuel in the line into the container. Then close the fuel gauge valve and disconnect the gauge.

Replace the Schrader valve cap.

Removing the Fuel Pump

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

Loosen the fuel tank filler cap to relieve the pressure inside the tank.

Lift the left rear seat cushion by hand.

Lift the carpet under the seat.

Detach the access door on the floor to reach fuel pump module on the fuel tank. Use a Phillips screwdriver.

Unplug the electrical connectors on the fuel pump module.

Disconnect the fuel pump module from the fuel lines using the 1/2-inch disconnect tool number 310-D005 or equivalent.

Unplug the vapor fuel line at the fuel pump module by squeezing the side tabs at the end of the fitting and pulling the line apart from the fitting.

Unscrew the fuel pump module from the fuel tank using the fuel tank sender wrench number 310-069 or equivalent.

Remove the fuel pump module and O-ring seal from the fuel tank.

Installing the New Fuel Pump

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

Install the fuel pump module in the tank along with a new O-ring seal. Screw the unit to the fuel tank using the fuel tank sender wrench.

Connect the vapor fuel line to the fuel pump module by pushing the line against its fitting until the locking tab snaps in place.

Connect the fuel pump lines to the fuel pump module by pushing the lines against their coupling fittings until the locking spring snaps in place.

Plug the electrical connectors to the fuel pump module.

Attach the access door using the Phillips screwdriver.

Replace the carpet.

Fold the left rear seat back into place.

Tighten the fuel tank filler cap.

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

Items you will need

  • Fuel pressure gauge (for engines other than the 2.0L model)

  • Container (for engines other than the 2.0L model)

  • Wrench

  • Phillips head screwdriver

  • Fuel line disconnect tool number 310-D005

  • Fuel tank sender wrench number 310-069

  • New O-ring seal

  • Slip joint pliers

 How to Install a Fuel Pump on a 2001 Ford Focus

Preparation

Siphon off as much fuel as possible if you can't wait until the fuel tank is nearly empty from running the car; use a vacuum pump or other siphon tool and deposit the fuel into a gas can.

Open the filler cap at the side of the car and remove the number 12 fuse from the fuse box. Start the car and wait for it to stall out, depressurizing the fuel system. Turn off the ignition and disconnect the negative battery cable.

Raise the rear end of the car, support it on jack or axle stands and block the front wheels with wheel chocks. Remove both rear wheels.

Tank/Pump Removal

Detach the exhaust flange at the exhaust system's front by removing the nuts behind the flexible pipe. Remove the exhaust heat shield by removing its flat nut fasteners with a flare nut wrench and unhooking the mounting rubbers at the front and rear ends of the exhaust system (this requires a special tool).

Move the disconnected exhaust system underneath the car so it is clear of the fuel tank. Support the system's front end with another axle stand and support the rear end with the car's rear suspension cross-member.

Disconnect the filler pipe and vent hose from the tank; loosen their clamps with a screwdriver or pliers. Disconnect the charcoal canister by pulling off its vapor hoses, releasing the fitting at the hose, pressing the metal clip and lifting the canister upwards.

Disconnect the fuel lines from the fuel filter; pry out the insert to release the fittings.

Raise a floor jack with a block of wood under the tank, unbolt the tank strap with a wrench and a socket extension, unhook the straps and lower the tank with the jack.

Disconnect the fuel lines from the fuel pump module; use a small screwdriver to release the lines' fitting lugs. Note that the fuel supply line connector has a white band while the return line connector has a red band.

Unscrew and remove the module's retaining ring. You can use an oil filter strap wrench or large slip joint pliers, but a special Ford-issued service tool (310-069) is recommended.

Withdraw the top cover for the current pump and sender unit and feed its wiring out through the hole. Turn the pump and sender unit counterclockwise and withdraw the unit from the fuel tank. Remove the rubber seal on the pump's periphery.

Tank/Pump Installation

Insert the fuel pump into the fuel tank. Make sure the pump is fully seated within the tank then turn it clockwise to secure it in the tank.

Connect the top cover for the pump and turn it so the arrows on the pump unit and the fuel tank line up. Install a new rubber seal on the fuel pump, then install and tighten the retaining ring with the same tool you removed it with.

Reconnect the fuel lines to the tank and lift it back into position on the car using the jack. Hook the straps back into place and secure them with the strap bolt.

Reconnect the fuel lines to the fuel filter, using the same red/white bands as a guide for the fuel pump connections. Reinstall the charcoal canister and reconnect the fuel filler pipe and vent hose to the tank with their clamps.

Maneuver the exhaust system back into place and connect the mounting rubbers, the heat shield and the exhaust flange.

Reconnect the rear wheels and lower the car. Pour the fuel back into the tank through the filler pipe on the side and reconnect the battery cable and the fuel pump fuse.

Turn the ignition key to the "On" position for about 10 seconds, turn it off and repeat twice more to repressurize the fuel system.

Items you will need

  • Vacuum pump

  • Gas can

  • Jack stands

  • Floor jack

  • Wood chocks

  • Tire iron

  • Wrench

  • Socket extension

  • Exhaust system mount removal tool

  • Pliers

  • Screwdriver

  • Wood block/plank

  • Ford retaining ring tool

  • Rubber fuel pump seal