E-Series Vans (1997-2005)

Fuel Pump


Removal & Installation

Fuel injection systems remain under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

  1. Before servicing the vehicle, refer to the Precautions Section.
  3. Remove or disconnect the following:

    Negative battery cable
    Fuel system pressure
    Fuel tank
    Fuel tank filler pipe vent hose and fuel tank filler pipe from the tank

  5. Support the fuel tank with a jack.

    The 2 fuel tank support strap nuts
    2 fuel tank support straps

    Click image to see an enlarged view

    Fig. Remove the mounting bolts (1), then lift the fuel pump assembly (2) out of the tank


  7. Lower the fuel tank to allow access to the electrical connections

    Fuel tank connections
    Fuel and electrical connections from the fuel pump
    Fuel tank
    Fuel tank screws/nuts, fuel pump and sender


To install:

  1. Install or connect the following:

    Fuel sender and fuel pump into the fuel tank. Tighten the screws/nuts to 89 inch lbs. (10 Nm).

  3. Raise the fuel tank.

    Fuel and electrical connections to the fuel pump
    Fuel tank connections
    Fuel tank support straps and tighten the nuts to

    1997-03 mid-ships tank: 13-17 ft. lbs. (17-23 Nm)
    1997-03 aft-of-axle tank: bolts 64-88 ft. lbs. (87-119 Nm); nuts 56-76 ft. lbs. (77-103 Nm)
    2004-05 mid-ships tank: 18 ft. lbs. (25 Nm)
    2004-05 aft-of-axle tank: bolts 76 ft. lbs. (103 Nm); nuts 66 ft. lbs. (90 Nm)
    Fuel tank filler pipe vent hose and the fuel tank filler pipe to the tank
    Negative battery cable