Replacing The Fuel Pump In Your Freestar: A Step-By-Step Guide

Changing a fuel pump on a Ford Freestar can be a complex task. The fuel pump is located in the vehicle's gas tank, and the process involves dealing with gasoline, which is highly flammable. While it is possible to attempt the replacement yourself, it is recommended to hire a professional mechanic to ensure safety and accuracy. The cost of replacing a fuel pump can vary, but it typically ranges from $200 to $600 for parts and labour. There are several signs that indicate a faulty fuel pump, such as whining noises from the fuel tank, backfires, and sputtering engines. If you notice any of these issues, it is important to address them promptly to avoid further complications.

Park car, locate pump assembly, and test pump

Park the car, locate the pump assembly, and test the pump

Park your car on a level surface and engage the parking brake. The fuel pump is located in the fuel tank, so you will need to locate an access panel above the tank in the passenger compartment. If there is no access panel, you will need to drain the fuel from the tank and then lower the tank from the vehicle to access the pump.

Once you have located the pump assembly, the next step is to test the pump to confirm that it is faulty. To do this, have someone turn the key to the "ON" position while you listen at the filler opening. A functioning fuel pump should hum for 2-3 seconds. If you don't hear this humming noise, it is likely that your fuel pump needs to be replaced.

Verifying the fuel pump relay and fuse

The next step is to locate and verify the vehicle's fuel pump relay and fuse. If the fuse is damaged, replace it with a new fuse of the same amperage. Once you have checked the fuse, you can move on to checking the fuel pump's operation.

Checking the fuel pump operation

If your vehicle's fuel pump is working, the issue may lie elsewhere. However, if the fuel pump is not working and the fuse and fuel pump relay are functioning correctly, you will need to check for power and ground at the fuel pump. If there is power and ground, you can conclude that the old pump is flawed and needs to be replaced.

Verify vehicle's fuel pump relay and fuse

To verify your vehicle's fuel pump relay and fuse, you'll first need to locate the fuse box, which is usually found under the hood near the front of your vehicle, or under the steering column. The fuel pump relay is typically green or grey. If you're having trouble finding it, check your vehicle's manual.

Once you've located the fuel pump relay, pull it straight out from the fuse box. You can then try putting a new relay in your fuse box and starting your vehicle. If it starts without a problem, the old relay is broken.

If your vehicle still doesn't work, you can test the old relay with a multimeter. First, clean the relay prongs with a wire brush to remove any rust or corrosion. Then, read the circuit diagram on the relay to identify which prongs to connect the power and multimeter to. Set your multimeter to the ohm setting, and attach jumper wires to the terminals on your vehicle's battery.

Connect the jumper wires to the positive and negative relay terminals, and listen for a clicking sound. If you don't hear a click, the circuit inside the relay isn't working.

Hold the multimeter probes against the remaining prongs on the relay. If the multimeter reads 0, the relay is functioning correctly. If the reading is greater than 0, the circuit inside the relay is faulty.

Check fuel pump operation

To check the fuel pump operation, you should park your car on a level surface and set the parking brake. Locate the pump assembly in the fuel tank and turn the key to the 'ON' position. The fuel pump should be audible for 2-3 seconds. If it doesn't make a sound, it needs to be replaced.

Next, locate and verify the vehicle's fuel pump relay and fuse. If the fuse is damaged, replace it with a new one of the same amperage. If the vehicle's fuel pump works, the issue is resolved. If it doesn't work and the fuse and relay are functioning, check for power and ground at the fuel pump. If there is power and ground, the pump is faulty and needs to be replaced.

Relieve fuel system pressure and disconnect negative battery cable

To relieve the fuel system pressure, a mechanic will turn the ignition key to the 'on' position and listen at the filler opening. The fuel pump should hum for 2-3 seconds. If it doesn't, the pump needs to be replaced.

Once the humming has stopped, the mechanic will locate and disconnect the negative battery cable. This is a safety precaution to prevent any electrical sparks, which could cause the fuel vapours to ignite.

The mechanic will then drain as much fuel as possible from the fuel tank. They will do this by disconnecting the filler fuel hose and the electrical connection to the old pump.

Next, they will support the fuel tank using a jack stand and a block of wood. This will prevent the tank from moving or falling during the rest of the procedure.

Now that the fuel system pressure has been relieved, and the negative battery cable has been disconnected, the mechanic can proceed to remove the fuel pump assembly.

Drain fuel tank, disconnect filler fuel hose, and remove pump assembly

To drain the fuel tank, you will need to locate the pump assembly in the fuel tank and turn the key to the 'ON' position. The fuel pump should hum for 2-3 seconds. Next, relieve the fuel system pressure and disconnect the negative battery cable. Then, drain as much fuel as possible from the tank.

Disconnecting the filler fuel hose involves first supporting the fuel tank using a jack stand and a block of wood. Then, disconnect the electrical connection to the old pump and remove the entire pump assembly, including the pump and the fuel level sending unit.

To remove the pump assembly, you will need to remove any hose clamps and disconnect the fuel line or fuel tank hose. Then, extract the original pump from the gas tank. Compare the new fuel pump to the old one to ensure you have the correct part, and then install the new pump by connecting all the fuel lines. Reinstall the straps and bolts, and reconnect the filler fuel and electrical connector. Finally, reconnect the negative battery cable.

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