Fuel Pump Module

updated 12/04/2003

Information | Removal and Installation

WARNING: THE UNLEADED GASOLINE FUEL PUMP MUST NOT BE SUBSTITUTED FOR THE FLEXIBLE FUEL VEHICLE FUEL PUMP, OR PREMATURE FUEL PUMP FAILURE WILL OCCUR.

The fuel system has a fuel pump relay (part of constant control relay module [CCRM]) controlled by the powertrain control module (PCM), which provides power to the fuel pump under various operating conditions.

When the ignition switch is in the OFF position the powertrain control module and fuel pump relays are not energized.
When the ignition switch is first turned to the RUN position:

The PCM power relay is energized.
Power is provided to both the fuel pump relay and to a timing device in the powertrain control module.
The fuel pump is supplied power by the fuel pump relay.

If the ignition switch is not turned to the START position the timing device in the powertrain control module will open the ground Circuit 57 (BK) (after approximately one second). Opening the ground circuit de-energizes the fuel pump relay, which in turn de-energizes the fuel pump. This circuitry provides for pre-pressurization of the fuel system.
When the ignition switch is turned to the START position the powertrain control module operates the fuel pump relay to provide fuel for starting the engine while cranking.
After the engine starts and the ignition switch is returned to the RUN position:

Power to the fuel pump is again supplied through the fuel pump relay.
The powertrain control module senses engine speed and shuts off the fuel pump by opening the ground circuit to the fuel pump relay when the engine stops or is below 120 rpm.

The fuel pump module is mounted in the module retainer (integral to fuel tank). The fuel initially enters the module through a flapper valve, located at the bottom of the module, and primes the fuel pump. A portion of the high pressure flow from the fuel pump is diverted to operate a venturi jet pump. The jet pump draws fuel from the fuel tank into the fuel pump module. This design permits optimum fuel pump operation during vehicle maneuvers and driving on steep hills with low-tank full levels.

This assembly includes a check valve which is inside the manifold outlet of the fuel pump module. The function of this valve is to maintain pressure in the system after the vehicle is shut down.

The pressure retention helps prevent hot starting concerns.

The fuel pump for the:

3.0L (2V) is capable of supplying 80 liters (21.1 gallons) of fuel per hour at 269 kPa (39 psi) at 13.2. volt.
3.0L (4V) engines are capable of supplying 120 liters (31.7 gallons) of fuel per hour at 269 kPa (39 psi) at 13.2. volt.
3.0L (2V) FF vehicle is capable of supplying 125 liters (33 gallons) of fuel per hour at 269 kPa (39 psi) at 13.2. volt.
3.4L (SHO) No specifications listed, but it is assumed to use the same pump as the 3.0L 4V listed above.

The fuel pump has an internal pressure relief valve to provide overpressure protection in the event the fuel flow becomes restricted (damaged lines, clogged fuel filter, etc.). Overpressure is restricted to 850 kPa (123 psi) and reduced fuel flow will result. The system pressure is controlled by a fuel pressure regulator mounted on the fuel injection supply manifold.

Removal

SPECIAL SERVICE TOOL(S) REQUIRED

Description Tool Number

Fuel Tank Sender Wrench T74P-9275-A

Multiport Fuel Injection (MFI) Fuel Pressure Gauge T80L-9974-B

1. Place vehicle on hoist but do not raise.

2. Install Multiport Fuel Injection (MFI) Fuel Pressure Gauge T80L-9974-B or Rotunda Fuel (Methanol/Ethanol) Pressure Test Kit 134-R0035 or equivalent (depending upon application) and depressurize fuel system.

3. Drain fuel from fuel tank through fuel tank filler pipe as described.

4. Raise vehicle on hoist.

5. Remove fuel tank and move to bench.

6. Remove any dirt that has accumulated around fuel pump module retaining flange so that it will not enter fuel tank during removal and installation.

7. Turn fuel pump module locking retainer ring counterclockwise using Fuel Tank Sender Wrench T74P-9275-A and remove fuel pump module locking retainer ring.

8. Pull fuel pump module sender plate up out of fuel tank until locking tabs for fuel pump module are accessible. Squeeze both locking tabs together and remove fuel pump module from fuel tank.

9. Remove O-ring seal and discard.

Installation

1. Clean fuel pump module retaining flange, fuel tank mounting surface and seal ring groove.

2. Apply a light coating of Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-BA on a new O-ring seal to hold it in place during assembly and install O-ring in seal ring groove.

3. Install fuel pump module carefully into fuel tank to make sure that filter, hoses and float rod are not damaged or binding. Align fuel pump module and fuel tank retainer axially and push fuel pump module into fuel tank retainer. When fuel pump module is engaged, a definite click will be heard and the (two) outside tabs on fuel pump module will be engaged on the outside of the fuel tank retainer. The fuel pump module must be snapped in the retainer with both tabs. Pull on fuel pump module to make sure it is fully engaged. Install fuel pump module sender plate to fuel tank, being careful that locating keys are in keyways and O-ring seal remains in place.

4. Hold assembly in place and install fuel pump module locking retainer ring finger-tight. Make sure that all locking tabs are under fuel pump module locking retainer ring tabs.

5. Secure fuel pump module unit by rotating fuel pump module locking retainer ring clockwise using Fuel Tank Sender Wrench T74P-9275-A until fuel pump module locking retainer ring snugs against stops.

6. Move fuel tank from bench to vehicle.

7. Install fuel tank in vehicle as described.

8. Lower vehicle.

9. Install a minimum of 38 liters (10 gallons) of fuel. Check for leaks.

10. Turn ignition switch to RUN position for three seconds repeatedly (5 to 10 times) until Multiport Fuel Injection (MFI) Fuel Pressure Gauge T80L-9974-B or Rotunda Fuel (Methanol/Ethanol) Pressure Test Kit 134-R0035 or equivalent (depending upon application) shows at least 207 kPa (30 psi). Check for leaks at fittings.

11. Remove Multiport Fuel Injection (MFI) Fuel Pressure Gauge T80L-9974-B or Rotunda Fuel (Methanol/Ethanol) Pressure Test Kit 134-R0035 or equivalent (depending upon application), start engine and recheck for leaks.

Item Part Number Description

9C385 Fuel Pump Locking Retainer Ring

9H307 Fuel Pump Module

-- Locking Tab (Part of 9H307)

9002 Fuel Tank

9E275 O-Ring Seal

-- Connector (Part of 14405 Wiring Assy)

Fuel Pump Module Terminals

Item Part Number Description

1 -- Fuel Return (Part of 9H308)

2 9H307 Fuel Pump Module

3 -- Sender Power (Part of 9H308)

4 -- Pump Power (Part of 9H308)

5 -- Sender Ground (Part of 9H308)

6 -- Pump Ground (Part of 9H308)

7 -- Foot (Part of 9H308)

8 -- Fuel Outlet (Part of 9H308)

For detailed photographs click on this link. Our thanks to Kirk for butchering another one for the cause!

http://www.venom.org/SHOfiles/fuel_pump

U.L

Contact Information

Description	Tool Number
Fuel Tank Sender Wrench	T74P-9275-A
Multiport Fuel Injection (MFI) Fuel Pressure Gauge	T80L-9974-B

Item	Part Number	Description
	9C385	Fuel Pump Locking Retainer Ring
	9H307	Fuel Pump Module
	--	Locking Tab (Part of 9H307)
	9002	Fuel Tank
	9E275	O-Ring Seal
	--	Connector (Part of 14405 Wiring Assy)