Sunday, May 4, 2014

How to Change a 96 Ford E350 Fuel Pump

The Ford E-Series is a line of full-size vans that has been in continuous production since 1961. The number in the series indicates the carrying capacity of the van, such that 350 indicates a carrying capacity of one ton. All versions of the E350 use electronic fuel injection, which requires the fuel pump to maintain the fuel system under high pressure. You must remove the fuel tank on the 1996 Ford E350 to replace the fuel pump.

Instructions

    1

    Detach the electrical connector for the fuel pump relay in the engine compartment and engage the starter for 10 seconds to empty the fuel system. Attach the electrical connector for the fuel pump relay. Disconnect the negative battery cable with a socket wrench to ensure you dont start the engine inadvertently while replacing the fuel pump. Siphon the fuel from the fuel tank with a hose and drain the fuel into a gasoline container.

    2

    Raise the vehicle and support it on jack stands. Disconnect the electrical connector for the fuel pump assembly and detach the fuel lines from the fuel tank. Support the fuel tank with a floor jack and disconnect the filler tube retainers with a socket wrench. Remove the straps for the fuel tank and lower the fuel tank with the floor jack. Move the fuel tank to your work area.

    3

    Clean the fuel tank around the fuel pump assembly with a shop towel to keep dirt out of the fuel tank. Turn the locking ring on the fuel pump assembly counterclockwise with a locking ring adapter for a 1996 Ford E350. Remove the locking ring from the fuel pump assembly and pull the fuel pump assembly out of the fuel tank. Discard the old gasket on the fuel tank.

    4

    Clean the mounting flange for the fuel pump assembly with a shop towel and coat the mounting flange with a thin layer of lubricant meeting Ford specification ESA-M1C75-B. Install the new gasket and fuel pump assembly into the fuel tank. Place the locking ring onto the fuel pump assembly and turn it clockwise until it locks into place.

    5

    Install the fuel tank by performing Step 2 in reverse and fill the fuel tank with fuel. Connect the negative battery terminal with a socket wrench. Turn the ignition on to pressurize the fuel system.


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