Repair 7

How to Replace the Fuel Pump in a 1994 Ford F 150

The Ford F-150 is a series of pickup trucks with a carrying capacity of one-half ton. The 1994 models use a single, high-pressure fuel pump that is part of a single In-Tank Reservoir (ITR) located within the fuel tank. The ITR also consists of the shuttle selector valve, the supply check valve and the venturi jet pump. You must therefore remove the fuel tank in order to replace the fuel pump in a 1994 Ford F-150.

Instructions

1

Disconnect the negative battery cable with a socket wrench to prevent the accidental discharge of fuel or electrical shock. Open the filler cap for the fuel tank to relieve the pressure in the fuel tank. Remove the valve cap on the fuel pressure relief valve on the fuel line in the engine compartments upper right corner. Attach pressure gauge T80L-9974-A to the relief valve and open the pressure gauge to relieve the pressure in the fuel system. Disconnect the pressure gauge and replace the valve cap.

2

Drain the fuel in the fuel tank by siphoning the fuel with a hose into a container suitable for gasoline. Disconnect the electrical wiring for the fuel gauge sending unit and detach the fuel lines from the fuel tank. Release the clamp for the filler neck and the filler neck from the fuel tank. Support the fuel tank with jack stands and remove the mounting bolts for the retaining strap on the fuel tank with a socket wrench. Remove the retaining straps for the fuel tank and lower the fuel tank to the ground.

3

Disconnect the electrical connector for the ITR and clean the fuel tank around the ITR with a shop towel. Detach the fuel lines from the ITR.

4

Turn the locking ring for the ITR counterclockwise with a hammer and wooden dowel. Remove the locking ring and lift the fuel pump from the fuel tank. Discard the old gasket on the fuel tank.

5

Place a new gasket on the fuel tank and install the new fuel pump into the the fuel tank. Fasten the locking ring by turning it clockwise until the locking ring stops against the retainer ring tab.

6

Complete the fuel pump replacement by performing steps 2 and 3 in reverse. Tighten the nuts for the retaining straps on the fuel tank to 30 ft. lbs. with a torque wrench. Fill the fuel tank and connect the negative battery terminal with a socket wrench.