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Fuel-Pump Replacement A Ford Ranger pick-up that refuses to start gets a thorough checkup and fuel-pump replacement. From "Weekend Mechanic" episode WKM-407

(Continued from page 2)

	Figure K
	Figure L

Removing the Old Fuel Pump

Safety Alert: When working on the fuel system, be sure to have a fire extinguisher handy and wear eye protection. It's also critical that you disconnect the battery while you are working on the fuel system.

• To get to our bad fuel pump we must first take off the truck bed, which requires removing six bolts (figure K). Penetrating oil will help make this job easier.

• While the penetrating oil soaks into the truck bed bolts, loosen and remove the fasteners that hold the fuel tank filler neck to the bed.

• Disconnect the taillight wiring harnesses. You can now lift off the bed to reveal the fuel tank (figure L).
  

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• Before replacing the fuel pump, do one last test to make sure it is the problem. Disconnect the electrical connection to the fuel pump and test the voltage using a multi-meter (figure M). Turn the vehicle on and off to test the voltage and see if it really is the problem.

• Use an air hose to remove dirt and debris so it doesn't get into the fuel tank.

  Detach the electrical connection.

  Figure M

  
  

  Figure N

• Then spray the area of the fuel pump with penetrating oil (figure N) to loosen the hose connections and fuel tank seal.

• Carefully detach the fuel hose connections. Ours are quick-connect fittings with a hairpin retainer clip (figure O).
  

• Use a screwdriver to carefully loosen the plastic fuel tank lock ring, being careful not to strip the threads (figure P).

  Important: Use caution when removing the lock ring. If the plastic fuel tank threads become damaged, you may have to replace the entire tank.

• Before removing the fuel pump assembly, note the arrow on the unit which corresponds to the mark on the tank. Then carefully remove the assembly.

  Figure O

  Figure P

  
  

  Bruce will replace the gas float for more accurate gas gauge readings.

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