How to Change the Fuel Pump in a 2003 Ford F-150 Super Crew

The 2003 Ford F-150 Super Crew pickup has a sequential fuel-injection system with a fuel injector for each cylinder, mounted in the intake manifold. Some fuel-injected vehicles have the fuel pump mounted on the chassis, near the fuel tank. Unfortunately, the F-150, like the majority of vehicles, has the fuel pump mounted in the gas tank with the fuel gauge sending unit. The fuel tank must be removed to replace the pump. While the F-150 Super Crew was available with several engine options, the procedure is the same for any engine except the optional 5.4-liter V-8 natural-gas engine.

Instructions

Removal

1

Park the F-150 on a level, paved surface. Drain the fuel tank into a gas can as much as possible with a siphon pump.

2

Pull around the edges of the kick panel -- located in front of the passenger door -- to disengage it from the clips that hold it to the body, to gain access to the fuel pump inertia switch. Unplug the electrical connector from the switch. Start the engine and allow it to run until it stops. This will relieve the fuel system pressure. Remove the negative battery cable.

3

Place wheel chocks in front of the front wheels. Raise the rear of the F-150 with a jack and support it with jack stands.

4

Remove the bolts from the fuel tank skid plate and remove the plate. The skid plate is directly under the fuel tank and attaches to the frame with four bolts.

5

Move between the fuel tank and the inside of the bed where the filler neck is located. Loosen the clamps on the fuel tank filler and vent hoses with a Phillips screwdriver. Pull the hoses from the filler neck and fuel tank.

6

Disconnect the electrical leads from the sending unit and fuel pump connector located on the driver side of the frame, near the tank.

7

Place a block of 2-by-4 inch wood on a floor jack. Raise the jack to support the fuel tank. Remove the bolts from the tank straps and pivot them away from the tank. Lower the tank enough so you can access the fuel lines.

8

Wrap masking tape around the metal fuel pump assembly lines and the supply and return lines. Number them with a marker so you can put them back in the right position. Pry the duckbill clips from the fuel line connectors at the fuel pump. Pull the fuel lines from the pump. Purchase new clips from an auto parts store for reassembly.

9

Lower and remove the tank. Mark the alignment marks an arrow on the fuel pump assembly and the dot on the tank with a marker to aid in reassembly.

10

Remove the six mounting bolts from the pump assembly. Slide the assembly out of the tank. Remove the rubber O-ring from the tank. The fuel pump should come with a new O-ring.

11

Unplug the electrical connector from the pump. Loosen the clamp that holds the pump onto the pump assembly. Remove the pump.

Installation

12

Mount the new pump on the assembly and tighten the clamp. Plug in the electrical connector. Coat a new O-ring with wheel bearing grease and seat it on the fuel tank. Slide the pump assembly into the tank. Line up the marks on the tank and pump assembly. Install and tighten the bolts.

13

Place the fuel tank on the jack and block of wood. Slide it under the F-150 and raise it into position. It will be easier to connect the fuel lines if you do this before the fuel tank is raised all the way up. Match up one of the fuel lines with the metal pipe on the pump assembly. Push the fitting onto the pipe so that the notch in the fitting passes the flare in the pipe. Install a new duckbill clip. Pull back on the fuel line to ensure that it is locked on the pipe. Repeat for the other fuel line.

14

Raise the fuel tank the rest of the way and swing the support straps into position, install and use a torque wrench to the bolts to 26 foot-pounds. Reconnect the electrical leads to the connector on the frame. Push the fuel filler and vent hoses onto the tank and filler assembly. Tighten the clamps. Mount the fuel tank skid plate and install the bolts. Use a torque wrench to torque the bolts to 11 foot-pounds.

15

Raise the F-150, remove the jack stands and lower it to the ground. Plug-in the inertia switch and replace the kick panel.