Vehicle: 1994 E250 4.9L

This vehicle had set for 3 years without being run by the previous owner, with about 8 gallons of gasoline left in it.

So the sending unit and fuel pump is heavily rusted and corroded. The yellow float wire corroded off the harness. The float plate is equally heavily rusted and corroded. Basically is junk.

So here is some preliminary information, the original sending unit and pump assembly is a Motorcraft PFS49 O'reilly cost is $486.99 and $516.21 after tax. Way more than I want to pay. Finding this particular 2 port pump is very difficult to find in a junk yard.

On a side note it is interesting that this pump is rated for a 22 gallon tank and the standard tank on this vehicle is a 35 gallon tank. There does not appear to be any wire tampering unless it is inside the black electrical shield.

From what I can discover the Motorcraft PFS47 is suppose to work for both the 2 port and 3 port fuel systems. It has three ports but when used on a 2 port system the third port is capped.

Here is the situation, I picked up a PFS47 pump from the junk yard not knowing that the sending unit wiring harness does not match, because the harness between the PFS49 and PFS47 are different. Also the wiring size is different. It appears that the original pump wiring is one size larger than the pump from the junk yard. As an example the original pump is maybe a size 14 wire and the pump from the junk yard is a size 16 wire.

I was thinking of cutting the sending unit wires off of the old pump at the base of the sending unit and then cutting the wires just behind the sending unit connector on the junk yard pump and splicing them together.

Can anyone see any problem with this? Can anyone see a problem with the original wire size being larger? Also the junk yard pump has the extra wire for the low fuel warning. Should this forth wire be connected if I spice the old connector on or should it be left off?

Any and all thoughts much appreciated.


Thanks

 

UPDATE:


I pulled back the wiring shield on the gas tank harness and discovered that the wires are the same size as the new pump. So what I think is that since the pump that was in there is rated for a smaller tank and the wire size on the sending unit is larger; I think that some one replaced the fuel pump before and used what ever was handy. I think that they replaced the original harness connector to install this wrong fuel pump.

So I am going to get a four prong connector and install this fuel pump.