Ford E7TZ-9C407-B Fuel Pump Assembly

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Issues in the fuel pump can result in insufficient fuel delivery or a lean condition in the engine.

For the removal of the mechanical fuel pump on carbureted models, begin by disconnecting the battery cable and placing a drain pan underneath. Remove the outlet pipe and inlet line at the fuel pump, plugging the end of the line to prevent leakage. Take out the bolts securing the fuel pump to the timing cover or engine block, and remove the pump along with the gasket. Clean the mating surfaces thoroughly. Installation involves placing a new gasket coated with RTV sealant, lubricating the fuel pump rocker arm, positioning the pump against the block or timing cover, and tightening the retaining bolts. Connect the inlet and outlet lines, reconnect the battery cable, and start the engine, checking for leaks.For the electric fuel pump on externally mounted, fuel-injected models from 1987 to 1989, relieve fuel system pressure and disconnect the battery cable. If necessary, raise the vehicle and locate the fuel pump along the inboard side of the left-side frame rail. Disconnect the electrical connector and fuel lines, remove the mounting bolts, and take out the pump. During installation, reset the inertia switch and ensure proper installation of pump fittings, wiring harness boots, and isolator. Reconnect the battery cable, start the vehicle, and check for proper pump operation and leaks.For the in-tank electric fuel pump, relieve fuel system pressure and remove the fuel tank. On plastic tanks, unscrew the locking ring and remove the pump/sending unit, while on metal tanks, tap the locking ring counterclockwise and remove the pump/sending unit. Installation involves coating the new sealing ring with grease, avoiding filter damage, aligning tabs in the pump/sending unit with tank flange slots, and reconnecting the battery cable. Start the vehicle and check for proper pump operation and leaks.

For 2.3L and 2.9L engines up to model year 1988, the electric fuel pump system consists of two fuel pumps: a low-pressure boost pump within the fuel tank and a high-pressure pump on the frame rail. To remove the low-pressure pump in the fuel tank, disconnect the negative battery cable, drain the tank or remove it, disconnect electrical connections to the fuel system sender unit, remove dirt around the fuel sender assembly, loosen the quick-connect fittings, and remove the locking ring, sender assembly, and sealing gasket. Then, install the fuel pump to the sender assembly, place a new sealing gasket in the tank's groove, and install the sender assembly into the tank. Rotate the locking ring to secure it. For the high-pressure pump on the frame rail, disconnect the negative battery cable, relieve system pressure, remove dirt and grease from fuel line fittings, disconnect quick-connect fittings properly, and remove the pump assembly from the mounting bracket. After cleaning and maintenance, reconnect electrical and fuel line connections, connect the battery cable, pressurize the fuel system, start the engine, and check for leaks. In 1989 and later models with 2.3L twin-plug, 2.9L, and 4.0L engines, a fuel tank and fuel pump/sender assembly are used. Disconnect the negative battery cable, depressurize the fuel system, drain the fuel tank, support it, and remove it along with the straps and shield. Remove dirt from the fuel pump flange, turn the fuel pump locking ring counterclockwise, and remove it. Then, remove the fuel pump and bracket assembly. To install a new seal ring gasket, clean the area thoroughly, coat the new seal ring with grease, and install it in the fuel ring groove. Position the pump/sender assembly in the tank, ensuring all keyways align and the seal ring remains in place. Rotate the locking ring clockwise and secure it to the specified torque. Reconnect the tank, fuel lines, vent line, and electrical connectors, and pressurize the fuel system. Finally, start the engine and check for leaks. To perform fuel pressure tests, use a diagnostic pressure valve located on the fuel supply manifold or install a pressure gauge with an adapter. Depressurize the fuel system before any disconnections.

Operational checks for the fuel pump involve verifying pump operation during startup and continuous running, addressing issues through diagnostic procedures, circuit checks, and pump replacements as necessary.

Before installing a new fuel pump, ensure that all gasket material is removed from the mounting pad and pump flange. Apply oil-resistant sealer to both sides of a new gasket and position it on the pump flange.

Three electric fuel pump configurations exist for F-series and Bronco vehicles: carbureted 7.5L engines with the "Hot Fuel" option utilize an in-tank low-pressure fuel pump, controlled by a fuel pump relay triggered by an engine oil pressure switch and powered through an inertia switch; early EFI models (pre-1990) employ a low-pressure in-tank pump and an externally mounted high-pressure pump, regulated by a pressure regulator on the fuel rail; later models (1990 and onward) feature an in-tank fuel delivery module (FDM) housing a high-pressure fuel pump, venturi jet pump, relief check valves, and shuttle selector valve. Operational checks involve verifying pump operation during startup and continuous running, addressing issues through diagnostic procedures, circuit checks, and pump replacements as necessary. For EFI models, additional engine off and running pressure checks, static pressure leakage checks, and in-tank low-pressure pump checks are performed to ensure proper fuel system function.

The fuel pump is positioned on the left front side of the block or timing chain cover.

Remove the inlet line at the fuel pump and plug the end of the line to prevent leakage.