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How Do I Install a Fuel Pump in a 1990 Ford Ranger

The Ranger is a pickup truck that Ford has produced since 1983. The 1990 Ford Ranger was equipped with either a 6-cylinder 2.9-liter engine or a 6-cylinder 4.0-liter engine, each of which uses fuel injection. The Ranger has an electric fuel pump in the fuel tank that produces low pressure. The pump is part of the fuel gauge sending unit, and you have to remove the entire unit if you need to replace the fuel pump and install a new one.

Instructions

1

Loosen the cap on the fuel tank and remove the air filter. Disconnect the cable from the negative battery terminal. Remove the valve cap from the pressure relief valve on the fuel rail. Connect fuel pressure gauge tool T80L-9974-A to the pressure relief valve. Open the pressure relief valve to relieve the pressure in the fuel system. Disconnect the fuel pressure gauge and replace the valve cap.

2

Drain the fuel from the fuel tank. Support the fuel tank with jack stands. Release the clamp on the fuel tanks fill pipe. Disconnect the bolts for the skid plate and remove the skid plate and its brackets from the fuel tank. Disconnect the bolts for the front and rear straps of the fuel tank and remove the straps. Release the clamp for the fuel sender units fuel hose. Remove the fuel lines from the fuel sender unit. Lower the tank from the Ranger with the floor jacks. Remove the shield from the fuel tank.

3

Detach the electrical connector from the fuel system sender unit. Clean the fuel tank around the fuel sender unit with a shop rag. Turn the locking ring on the fuel sender unit counterclockwise with a hammer and brass drift. Remove the locking ring from the fuel sender unit and pull the fuel sender unit from the fuel tank. Discard the sealing gasket. Detach the fuel pump from the fuel sender unit.

4

Insert the new fuel pump into the fuel sender unit. Put a new sealing gasket on the fuel tank. Place the fuel sender unit into the fuel tank and align the fuel senders tabs with the fuel tanks slots. Attach the locking ring to the fuel sending unit and turn it clockwise until the ring tab is against the stop. Attach the electrical connector for the fuel sender unit.

5

Reinstall the fuel tank. Reconnect the negative cable on the battery. Turn the ignition on for five seconds, then turn it off. Repeat at least five times to pressurize the fuel system. Start the engine and check for fuel leaks.