Repair 7

Instructions to Repair the Fuel Pump of a 1991 Ford Econoline 250

The Ford E-Series, or Econoline, is a line of full-size cargo and passenger vans. The number indicates the carrying capacity, with the 250 designator indicating a 3/4 ton carrying capacity. The 1991 Ford Econoline 250 was available with several eight-cylinder engines, all with fuel injection. This vehicle uses a high-pressure fuel pump that is part of the fuel sender assembly located in the fuel tank. You must remove the fuel tank to service the fuel pump in a 1991 Ford Econoline 250.

Instructions

1

Disconnect the electrical connection for the fuel pump relay and start the engine. Run the engine until it stalls. Crank the engine for five seconds to ensure the fuel system is empty. Connect the electrical connection for the fuel pump relay.

2

Disconnect the cable on the negative battery terminal with a socket wrench. Use a floor jack to raise the van onto jack stands. Siphon the fuel out of the fuel tank through the filler cap opening. Detach the electrical connections for the fuel sending unit and fuel pump. Disconnect the fuel lines from the fuel tank. Place a piece of wood on a floor jack and move the floor jack under the fuel tank. Raise the floor jack to support the fuel tank. Loosen the retainers for the filler tube and the fuel tank straps. Lower the floor jack and remove the tank from the vehicle.

3

Clean the surface of the fuel tank around the fuel sender assembly with a shop rag. Turn the locking ring on the fuel sender assembly counterclockwise with a hammer and brass drift punch. Remove the locking ring and remove the fuel sender assembly from the fuel tank. Discard the gasket for the fuel sender assembly.

4

Clean the mounting flange on the fuel tank and apply a thin layer of grease with Ford specification ESA-M1C75-B. Place the new gasket into the groove on the fuel tank. Install the fuel sending unit into the fuel tank, and align the tabs on the fuel sending unit with the slots in the fuel tank.

5

Tighten the locking ring for the fuel sending unit clockwise until it stops. Install the fuel tank. Connect the electrical connectors and fuel lines for the fuel sending unit. Lower the vehicle. Fill the fuel tank with fuel. Connect the cable for the negative battery terminal.