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    Ford Ranger/Bronco II 1983-1990 Repair Guide

    Electric Fuel Pump

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    REMOVAL & INSTALLATION



    2.3L And 2.9L Engines Through 1988

    On the 2.3L and the 2.9L engines to model year 1988 the electric fuel pump system used on these EFI engines consisted of two fuel pumps: a low pressure boost pump mounted in the fuel tank, and a high pressure fuel pump mounted on the frame rail.

    The low pressure electric fuel pump is located in the fuel tank and is a part of the fuel gauge sending unit.

    INTERNAL PUMP IN FUEL TANK

    See Figures 1, 2, 3, 4 and 5



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    Fig. Fig. 1: Exploded view of the low pressure fuel pump and sender



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    Fig. Fig. 2: Exploded view of the fuel sender locking ring assembly



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    Fig. Fig. 3: Cleaning the area around the sending unit



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    Fig. Fig. 4: Removing the lockring



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    Fig. Fig. 5: Removing the sending unit and low pressure fuel pump

    The low pressure fuel pump is located in the fuel tank and may require removal of the fuel tank assembly. Refer to Fuel Tank Removal and Installation procedures in this section as necessary.

    1. Disconnect the negative battery cable. Remove the fuel from the tank or remove the tank assembly.
    2.  
    3. Disconnect all electrical connections to the fuel system sender unit.
    4.  
    5. Remove any dirt around the fuel sender assembly.
    6.  
    7. Loosen the Quick Connect Fittings. Turn the fuel sender locking ring counterclockwise with special tool or equivalent (brass drift pin) remove the locking ring, sender assembly and sealing gasket. Remove the fuel pump from the fuel sender assembly.
    8.  

    To install:
    1. Install the fuel pump to sender assembly. Place a new sealing gasket in the groove of the fuel tank. Install the fuel sender assembly in the fuel tank so that the tabs of the sender are positioned into the slots of the fuel tank. The sealing gasket must remain in place during and after the fuel sender installation.
    2.  
    3. Holding the fuel sender and sealing gasket in place, install and rotate the locking ring clockwise until the stop is against the retainer ring tab.
    4.  
    5. Install the tank assembly as necessary. Connect all electrical and fuel line connections.
    6.  
    7. Refill the tank, connect battery cable, pressurize the fuel system. Start engine and check for leaks.
    8.  

    EXTERNAL FRAME MOUNTED PUMP ASSEMBLY

    See Figures 6, 7, 8, 9 and 10



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    Fig. Fig. 6: View of the externally mounted high pressure fuel pump assembly



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    Fig. Fig. 7: To remove the external fuel pump, first relieve the fuel system pressure and disconnect the fuel lines from the pump ...



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    Fig. Fig. 8: ... as well as the electrical connection



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    Fig. Fig. 9: Remove the fuel pump bracket attaching bolts and/or nuts, and pull the assembly from the frame rail



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    Fig. Fig. 10: Finally, remove the pump from its mounting bracket by unbolting the half-round retaining shield and lifting the pump out

    The high pressure fuel pump is frame mounted and can be accessed from under the vehicle. The fuel pump assembly is retained to the frame with 3 bolts. Remove the fuel pump and bracket assembly (disconnect electrical connector) from the frame of the vehicle. Before removing the fuel pump assembly, disconnect the negative battery cable and relieve the system pressure. Refer to "BLEEDING THE FUEL SYSTEM/RELIEVE FUEL PRESSURE'' procedure in this section.

    Clean all dirt and/or grease from the fuel line fittings. "Quick Connect'' fittings are used on all models equipped with a pressurized fuel system. These fittings must be disconnected using the proper procedure or the fittings may be damaged. Remove the fuel pump assembly from the metal mounting bracket. Remove the fuel pump. Install the fuel pump to mounting bracket and install the assembly to frame of the vehicle. Connect all electrical and fuel line connections, connect battery cable, pressurize the fuel system. Start engine and check for leaks.

    2.3L Twin Plug, 2.9L and 4.0L Engines

    On the 2.3L twin plug engine and the 2.9L and 4.0L engines starting in model year 1989 the electric fuel injection system uses a fuel tank and fuel pump/sender assembly.

    1. Disconnect the negative battery cable. Depressurize the fuel system. Refer to the necessary service procedure in this section.
    2.  

    On Ranger vehicles the fuel pump/sender unit may be serviced by removing the pick-up box from the chassis, instead of removing the fuel tank assembly.


    CAUTION
    The fuel system is under pressure. Release pressure slowly and contain spillage. Observe no smoking/no open flame precautions. Have a Class B-C (dry powder) fire extinguisher within arm's reach at all times.

    1. Drain the fuel tank. Drain the gasoline into a suitable safety container and take precautions to avoid the risk of fire. Remove the fuel filler tube.
    2.  
    3. Support the fuel tank assembly and remove the fuel tank supports straps. Lower fuel tank partially and remove all other connections. Remove the bolt from the front strap and remove the front strap. Remove the bolt from the rear strap and remove the rear strap.
    4.  
    5. Remove the fuel feed hose at the fuel gauge sender push connector.
    6.  
    7. Remove the fuel hose from the sender unit push connector.
    8.  
    9. Remove the fuel vapor hose from the vapor valve.
    10.  
    11. Lower the fuel tank from the chassis.
    12.  
    13. Remove the shield from the fuel tank.
    14.  
    15. Remove any dirt from the fuel pump flange.
    16.  
    17. Turn the fuel pump locking ring counterclockwise to remove it. There is a special wrench for this purpose, but you can loosen the ring by tapping it around with a wood dowel and plastic or rubber mallet.
    18.  


    CAUTION
    Never hammer on or near the fuel tank with metal tools! The risk of spark and explosion is always present!

    1. Remove the fuel pump and bracket assembly.
    2.  
    3. Remove and discard the seal ring gasket.
    4.  


    WARNING
    Do not attempt to apply battery voltage to the pump to check its operation while removed from the vehicle, as running the pump dry will destroy it!

    To install:
    1. Clean the area thoroughly.
    2.  
    3. Coat the new seal ring with multi-purpose grease to hold it in place and install it in the fuel ring groove.
    4.  
    5. Position the pump/sender assembly in the tank making sure that all keyways align and the seal ring stays in place.
    6.  
    7. Hold the fuel sender and sealing gasket in place, install and rotate the locking ring. Find the fuel tank part number on the front bottom of the tank, for vehicles equipped with E59A-9002-CAE tank: tighten the ring to 60-85 ft. lbs. wait 5 minutes and tighten again to 60-85 ft. lbs. For this tank assembly use the same ring that was removed from the tank. Do not replace the ring with a ring from another tank.
    8.  
    9. For tanks equipped with plastic retaining rings E99A-9A37-D, tighten nuts to 40-55 ft. lbs. use the same ring that was removed from the tank. If a new tank is installed, use a new ring.
    10.  
    11. For E69A-9002-PA tanks: tighten the locknut ring once to 80-113 ft. lbs. and for some vehicles tighten the polyethylene lock ring to 40-45 ft. lbs.
    12.  
    13. Support the tank assembly while connecting the fuel lines, vent line and electrical connectors.
    14.  
    15. Install the tank in the vehicle and tighten the retaining straps evenly. Make sure all gasket/rubber insulation if so equipped for retaining straps is in correct position.
    16.  
    17. Install filler tube.
    18.  
    19. Refill tank, pressurize the fuel system. Refer to the necessary service procedure in this section. Check complete system for fuel leaks at fittings.
    20.  
    21. Start engine and recheck for fuel leaks.
    22.  

    TESTING



    See Figures 11, 12, 13 and 14


    CAUTION
    Fuel pressure must be relieved before attempting to disconnect any fuel lines.

    The diagnostic pressure valve (Schrader valve) is located on the fuel supply manifold (rail). This valve provides a convenient point for service personnel to monitor fuel pressure, release the system pressure prior to maintenance, and to bleed out air which may become trapped in the system during pressure replacement. A pressure gauge with an adapter is required to perform pressure tests.

    Click image to see an enlarged view

    Fig. Fig. 11: Fuel pressure can be checked using an inexpensive pressure/vacuum gauge

    If the pressure tap is not installed or an adapter is not available, use a T-fitting to install the pressure gauge between the fuel filter line and the throttle body fuel inlet or fuel rail.

    To test the fuel pump, follow the accompanying diagnostic charts. Testing fuel pressure requires the use of a special pressure gauge (Ford Tool T80L-9974-B, Rotunda Fuel Pressure Testing Kit 014-00447, or equivalent) that attaches to the diagnostic pressure tap fitting. To perform the fuel system test a scan tool is necessary to access the different test modes.

    Depressurize the fuel system before disconnecting any lines.



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    Fig. Fig. 12: Fuel pressure test chart-part 1



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    Fig. Fig. 13: Fuel pressure test chart-part 2



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    Fig. Fig. 14: Fuel pressure test chart-part 3

     
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