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john -aka eauto
john -aka eauto, The Car Guy
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How do i change a fuel pump on a 99 Expedition, 5.4L?

Customer Question

How do i change a fuel pump on a 99 Expedition, 5.4L?
Submitted: 7 years ago.
Category: Ford
Expert:  john -aka eauto replied 7 years ago.
Service and Repair
Notes

Fuel Tank Wrench


SPECIAL SERVICE TOOLS

REMOVAL

  1. Remove the fuel tank.

See: Fuel Tank

  1. Clean the area around the fuel pump mounting flange.

  1. Remove the fuel pump.
1Using the Fuel Tank Wrench, remove the fuel tank sending unit locking retainer ring
2Remove the fuel pump.

NOTE: The fuel pump must be handled carefully to avoid damage to the float arm and filter.

  1. Remove and discard the fuel pump mounting gasket.

INSTALLATION

  1. Clean the fuel pump mounting flange and the fuel tank mounting surface.
  2. Install the fuel pump mounting gasket. NOTE: Apply a light coat of Premium Long Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B to the gasket to hold it in position during assembly.

  1. Install the fuel pump and finger tighten the fuel tank sending unit locking retainer ring.
  2. Using, the Fuel Tank Wrench, tighten the fuel tank sending unit locking retainer ring
  3. Install the fuel tank.

 

Removal and Installation
Notes

Fuel Line Disconnect Tool


SPECIAL SERVICE TOOLS

REMOVAL

WARNING
  • DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY.
  • FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD.

  1. Perform the Fuel Pressure Release Procedure.
  2. Disconnect the battery ground cable.
  3. Raise and support the vehicle.
  4. Drain the fuel from the fuel tank.

  1. Disconnect the fuel tank filler pipe vent hose from the fuel tank filler pipe.

  1. Disconnect the fuel pump electrical connector.

  1. Position a suitable jack under the fuel tank.

  1. If equipped, remove the fuel tank skid plate.
1Remove the bolts.
2Lower the fuel tank skid plate.

  1. Remove the front fuel tank support strap.
1Remove the bolts.
2Remove the front fuel tank support strap.

  1. Remove the rear fuel tank support strap.
1Remove the bolts.
2Remove the rear fuel tank support strap.

  1. Partially lower the fuel tank and disconnect the two Evaporative (EVAP) emissions hoses.

  1. Disconnect the two safety clips from the fuel lines.

  1. Use the Fuel Line Disconnect Tool to disconnect the fuel lines from the fuel pump.

  1. Lower the fuel tank.

INSTALLATION





  1. To install, reverse the removal procedure.

 

 

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