REMOVAL & INSTALLATION
See Figures 1 through 5
Fig. 1: Typical in-tank electric fuel pump assembly
The electric fuel pump used in these models is located in the fuel tank and is removed as a unit with the fuel sender.
Release the fuel system pressure. Disconnect the negative battery cable.
Remove the fuel tank.
Place the tank on a workbench and clean the dirt from around the pump/sender assembly locking ring area.
Turn the locking ring counterclockwise to remove it.
Lift out the fuel pump and sending unit. Discard the gasket.
On E-series cutaway vans, the pump and sending unit is retained by bolts.
Fig. 2: A special tool is usually available to remove or install the fuel pump locking cam
Fig. 3: A brass drift and a hammer can be used to loosen the fuel pump locking cam
Fig. 4: Once the locking cam is released, it can be removed to free the fuel pump
Clean the pump mounting flange and put a light coating of grease meeting Ford specification ESA-M1C75-B or its equivalent to hold the new gasket in place.
Place a new gasket in position in the groove in the tank.
Place the sending unit/fuel pump assembly in the tank, indexing the tabs with the slots in the tank. Make sure the gasket stays in place.
Hold the assembly in place and tighten the locking ring clockwise.
Connect the fuel lines and wiring.
Install the fuel tank.
Fig. 5: The fuel system may be equipped with a cut-off switch; refer to underhood labels or your owner's manual for more information
See Figures 6 through 12
Fig. 6: The external pump is mounted on the frame rail
Fig. 7: Unplug the fuel pump electrical connections
CAUTION Never smoke when working around gasoline! Avoid all sources of sparks or ignition. Gasoline vapors are EXTREMELY volatile!
Depressurize the fuel system.
Disconnect the negative battery cable.
Disengage the pump electrical connections.
Raise and support the rear of the vehicle on jackstands.
Disconnect the inlet and outlet fuel lines.
Remove the pump from the mounting bracket.
Fig. 8: Use a prytool to disengage the fuel line retaining clip
Fig. 9: After the clip is loosened, grasp it and pull it from the line
Fig. 10: Unfasten the pump to bracket retainers
Fig. 11: Disconnect the front fuel line from the pump
Fig. 12: Slide the pump out to gain access to the rear fuel line and disconnect it in the same manner as the front
Make sure the pump is indexed correctly in the mounting bracket insulator and tighten the retainers.
Engage the fuel lines.
Lower the van.
Connect the negative battery cable and check for leaks.
Operate the engine at the specified idle rpm.
Open the hose restrictor and catch the fuel in the container while observing the time it takes to pump 1 pint. 1 pint should be pumped in 20 seconds. If the pump does not pump to specifications, check for proper fuel tank venting or a restriction in the fuel line leading from the fuel tank to the carburetor before replacing the fuel pump.
See Figure 13
Connect a fuel gauge to the pressure test point (shrader valve) on the fuel rail.
With key ON engine OFF the readings should be as follows:
1989-94 4.9L engines: 50-60 PSI (345-415 kPa)
1989-94 5.0L, 5.8L and 7.5L engines: 35-45 PSI (240-310 kPa)
1995-96 all engines: 35-45 PSI (240-310 kPa)
With key ON engine ON the readings should be as follows:
1989-94 4.9L engines: 45-60 PSI (310-415 kPa)
1989-94 5.0L, 5.8L and 7.5L engines: 30-45 PSI (210-310 kPa)
1995-96 all engines: 30-45 PSI (210-310 kPa)
Fig. 13: Fuel pressure can be checked using an inexpensive pressure/vacuum gauge