How do you change fuel pump in 1991 Ford Aerostar

 

The fuel pump for the 3.0L and 4.0L engines is part of the fuel gauge sender unit. To access this fuel pump the gas tank must be removed.
In the event the fuel sender or fuel pump fails, the entire unit must be removed and replaced.
[*]Disconnect the negative battery cable.[*]Depressurize the fuel system and drain the fuel tank. Drain the gasoline into a suitable safety container and take precautions to avoid the risk of fire.[/ol]
[/align][/align]CAUTION[/align]
The fuel system is under pressure. Release pressure slowly and contain any spillage. Observe no smoking/no open flame precautions. Have a Class B-C (dry powder) fire extinguisher within arm's reach at all times.[/align][/align][*]Loosen the gas tank filler pipe clamp.[*]Remove the bolt from the front strap and remove the gas tank front strap.[*]Remove the bolt from the rear strap and remove the gas tank rear strap.[*]Remove the fuel feed hose at the fuel gauge sender push connector.[*]Remove the fuel hose from the sender unit push connector.[*]Remove the fuel vapor hose from the vapor valve.[*]Slowly lower the fuel tank from the chassis.[*]Remove the shield from the fuel tank.[*]Remove any dirt from the fuel pump flange.[*]Turn the fuel pump locking ring counterclockwise to remove it. There are wrenches for this purpose, but you can loosen the ring by tapping it around with a wood dowel and plastic or rubber mallet.[/ol]

CAUTION[/align]Never hammer on or near the fuel tank with metal tools! The risk of spark and explosion is always present![/align][/align][*]Remove the fuel pump and bracket assembly. Discard the rubber O-ring.[/ol]

WARNING[/align]Do not attempt to apply battery voltage to the pump to check its operation while removed from the vehicle. Running the pump dry will destroy it.[/align][/align]To install:

[*]Clean the around the fuel pump hole.[*]Coat the new O-ring with multi-purpose grease to hold it in place. Install the O-ring in the ring groove on the fuel pump.[*]Position the pump assembly in the tank making sure the keyways align and the seal ring remains stays in place.[*]Tighten the locking ring to 40-50 ft. lbs. (52-65 Nm).[*]Install the shield on to the fuel tank.[*]Raise the tank into position and support until all the straps are secured in place.[*]Connect the hoses and wires to the sender assembly.[*]Attach the rear strap to the vehicle.[*]Attach the front strap.[*]Install the fuel lines to the feed and return hoses at the fuel gauge sender push connector.[*]Install the filler pipe in position and tighten the filler pipe clamp.[*]Install the front and rear fuel tank mounting bolts and tighten them to 35-45 ft. lbs..[*]Connect the negative battery cable. Road test the vehicle.[/ol]

 

[quote]ORIGINAL: Use Common Sense

The fuel pump for the 3.0L and 4.0L engines is part of the fuel gauge sender unit. To access this fuel pump the gas tank must be removed.
In the event the fuel sender or fuel pump fails, the entire unit must be removed and replaced.[*]Disconnect the negative battery cable.[*]Depressurize the fuel system and drain the fuel tank. Drain the gasoline into a suitable safety container and take precautions to avoid the risk of fire.
[ol][/ol]
[/align][/align]CAUTION[/align]
The fuel system is under pressure. Release pressure slowly and contain any spillage. Observe no smoking/no open flame precautions. Have a Class B-C (dry powder) fire extinguisher within arm's reach at all times.[/align][/align][*]Loosen the gas tank filler pipe clamp.[*]Remove the bolt from the front strap and remove the gas tank front strap.[*]Remove the bolt from the rear strap and remove the gas tank rear strap.[*]Remove the fuel feed hose at the fuel gauge sender push connector.[*]Remove the fuel hose from the sender unit push connector.[*]Remove the fuel vapor hose from the vapor valve.[*]Slowly lower the fuel tank from the chassis.[*]Remove the shield from the fuel tank.[*]Remove any dirt from the fuel pump flange.[*]Turn the fuel pump locking ring counterclockwise to remove it. There are wrenches for this purpose, but you can loosen the ring by tapping it around with a wood dowel and plastic or rubber mallet.
[ol][/ol]

CAUTION[/align]Never hammer on or near the fuel tank with metal tools! The risk of spark and explosion is always present![/align][/align][*]Remove the fuel pump and bracket assembly. Discard the rubber O-ring.
[ol][/ol]

WARNING[/align]Do not attempt to apply battery voltage to the pump to check its operation while removed from the vehicle. Running the pump dry will destroy it.[/align][/align]To install:[*]Clean the around the fuel pump hole.[*]Coat the new O-ring with multi-purpose grease to hold it in place. Install the O-ring in the ring groove on the fuel pump.[*]Position the pump assembly in the tank making sure the keyways align and the seal ring remains stays in place.[*]Tighten the locking ring to 40-50 ft. lbs. (52-65 Nm).[*]Install the shield on to the fuel tank.[*]Raise the tank into position and support until all the straps are secured in place.[*]Connect the hoses and wires to the sender assembly.[*]Attach the rear strap to the vehicle.[*]Attach the front strap.[*]Install the fuel lines to the feed and return hoses at the fuel gauge sender push connector.[*]Install the filler pipe in position and tighten the filler pipe clamp.[*]Install the front and rear fuel tank mounting bolts and tighten them to 35-45 ft. lbs..[*]Connect the negative battery cable. Road test the vehicle.
[ol]Thanks for the info[/ol]