Fuel Pump: Service and Repair

CAUTION: Fuel supply lines remain pressurized for long periods of time after the engine is shut down. This pressure must be relieved before the fuel system is serviced: Fuel Pressure Release

NOTE: On some vehicles, fuel tank sending unit is not available separately. On those vehicles, to replace sending unit, replace entire fuel pump .

Removal

1. Remove fuel tank: Service and Repair

2. Remove fuel tank to bench. Remove any dirt that has accumulated around the fuel pump attaching flange so that it will not enter the fuel tank during fuel pump removal.






3. Turn the fuel tank sending unit locking retainer ring counterclockwise with the Fuel Tank Lock Ring Wrench T90T-9275-A or Fuel Tank Sender Wrench T86T-9275-A and remove fuel tank sending unit locking retainer ring.

4. Remove the fuel pump and sender assembly.

5. Remove fuel pump mounting gasket and discard.

6. If necessary, disconnect spade connector and remove two screws and fuel tank sending unit.

Installation

1. If necessary, install fuel tank sending unit and two screws. Connect spade connector.

2. Clean the fuel pump mounting flange and the fuel tank mounting surface and groove in fuel tank sending unit locking retainer ring.

3. Put a light coating of Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B on a new fuel pump mounting gasket to hold it in place during assembly and install it in the fuel ring groove.

4. Install fuel pump and sending unit assembly carefully to make sure that the filter is not damaged. Be sure that the locating keys are in keyways and the fuel pump mounting gasket remains in place.

5. Hold the fuel sending unit and fuel pump mounting gasket in place. Install and rotate the fuel tank sending unit locking retainer ring clockwise using Fuel Tank Lock Ring Wrench T90T-9275-A.

6. Tighten the fuel tank sending unit locking retainer ring to 55-74 Nm (40-55 lb.ft.).

7. Install fuel tank: Service and Repair