My 90 3.0L with 197,000 miles started acting up Sunday evening (why is it always at the end of the weekend ) symptoms were lose of power and check engine light while heading up a hill about 2 miles after a cold start. Pulled onto a side street and engine died. Restarted right away, no check engine light and ran fine for a couple of more miles and then same thing, lost power and check engine light. Got it home and pulled the codes and got nothing. While running KOER tests it dies but no codes. Did notice that the fuel pump seems to be running more than usual. Next day cold starts fine and runs about 5 minutes at idle then dies. Replaced the fuel filter (it has been a long time since it was changed) but same symptoms, runs for about 5 minutes at idle then dies. Haven't checked the fuel presure but I'm thinking it is the fuel pump; planning to pick up a new one at the local NAPA store tomorrow.
Any other ideas?
Anyone replace a fuel pump and have some tips or tricks to share?

 

I just replaced my 94 4.0L fuel pump today. After get the parts (new assembly pump, in-line filter, a lot of clean rags), put the van on racks and jack up. Make sure you work in a vent and safe area and have the distinguisher at hands, don't make any spark or smoke. Here what I done:

1) Disconnect the neg. battery cable
2) Siphon the gas out as much as possible.
3) De-pressure the gas line
4) loosen the clam (at the filler pipe)
5) Remove the gas tank fire wall (5 screws)
6) Set the transmission jack to support the tank
7) Disconnect the connector just outside of the tank (to the front)
8) Remove the 2 inner bolts of the 2 tank traps
9) Remove the 2 tank traps
10) Drop the transmission jack down about 3", 4" or so and gently pull the tank down. It might stuck with the sticky insulation of the traps
11) Disconnect the pump electric supply connector which has 3 snaps to hook to the pump (I use a small flat screwdriver pry the bottom snaps GENTLY)
12) Disconnect the gas feed and return lines from the pump
13) Disconnect the 2 vents (locate at the rear-top of the tank)
14) Drop the tank down another 7" or so then disconnect the filler pipe from the metal neck (I had to twist the pipe back & forth) and pull it down with the tank. You better have a helper to hold the tank.
15) Clean around the pump surface real good, and then use big jaw pliers to open the pump cap. Mine is white plastic. Clean it thru.
Replace with the new one. DO NOT test it dry, the test will ruin the pump in that condition. Set the 2 arrow marks on the pump lid to match with the 2 marks on the tank then hand-tight the pump cap and use the pliers to tight it a half more turn. In my case I try to clean the inside of the tank but I couldn't find/see any dust. Put the tank back and use the 2 new plastic clams, which supply with the new unit, to secure the feed & return lines. Reconnect all by reverse above sequence then change the fuel filter, clean all the spill gas, fill your gas tank about 5 gallons or more if possible. Re-connect the battery negative cable. Turn the key on for a few seconds then turn off a few seconds; repeat it 6 times before fire up the car.
Hope it helps,
Fordboy49

 

I've made a hatch to acces a pump from inside the van! Recomend to all!

 

Pablo, please tell us you didn't do this with your "fire wrench", (oxy-acetylene torch).

Otherwise, a good idea, something Ford should have provided - our '91 Escort-GT has a similar access panel. Sure is convenient. On the other hand, the original pumps were pretty good, most (including my own) are still going after 15+ years.

 

How can I use "fire wrench"? Tank is full and made of plastic! I used electric cutter!


20 min. job! Close the holo with metal panel (use foam-rubber gasket!) and screw it with 6 bolts!

 

Just kidding you Pablo - weird American humor. (I was recalling the pictures of your recent rear brake job when I wrote that.)

 

Pablo,
maybe aerocolorado was thinking of all those hot fiery Bulgarian wench's you take on wine tasteing trips to the lake

 

Sounds like your fuel pump went bad, but to be sure you really need to hook up a fuel pressure gauge and watch it while your engine runs. (Or dies!)

 

Thanks for the ideas. Spent this evening getting the gas out of the tank (aprox. 15 gallons as I had 3/4 of a tank). Plan is to drop the tank tomorrow night. Already have the new pump.

 

Aerocolorado ! My rear brake were not served for 5 years! I could not remove drums! Big hammer did not help me!

The most popular Ford here is Focus, and there are many recomendations, how to remove fuel pump, remooveing no tank! One more recomendation with picturies (unfortunatly the text is russian...)




http://www.zr.ru/arch43865.html

 

Just to let everyone know the instructions posted by Fordboy49 were right on. Did the fuel pump on Saturday by myself. Not a hard job, the worst part for me was the tank strap bolts. Started out doing them by hand but then switched to the air wrench because they were long and fighting all the way! Took about 4 hours not including time to drain the gas. Used a floor jack to help lower and raise the tank, a second pair of hands would have been a big help putting it back. Empty the tank assembly does not weight much but is a bit awkward to get back into place.

 

I can replace pump in 20 minutes, draning no gas! But of course I mast be carefull with imflamable gas and doors must be open!