Replacing Fuel Pump In 2003 Ford Expedition: Step-By-Step Guide

If your 2003 Ford Expedition is having trouble starting, it may be time to replace the fuel pump. The fuel pump is located in the fuel tank and can be accessed by dropping the fuel tank or by removing the rear seat and cutting an access panel. The pump itself costs between $140 and $360, and you can find it at AutoZone. The process of replacing the fuel pump involves releasing the fuel system pressure, draining the fuel tank, disconnecting the vapor hoses, removing the fuel tank skid plate, disconnecting the fuel pump electrical connector, and then removing the fuel tank. It is important to note that you should not support the fuel tank directly beneath the fuel pump mounting area to avoid damaging the fuel pump assembly. Once the fuel tank is removed, you can disconnect the quick-release fittings from the fuel pump and remove the fuel pump lock ring and assembly. Finally, you can install the new fuel pump assembly and reconnect all the components that were disconnected.

The fuel pump is located in the fuel tank

The fuel pump is located inside the fuel tank of your 2003 Ford Expedition. This means that, to access the fuel pump, you will need to remove the fuel tank from the vehicle.

• Release the fuel system pressure.
• Drain the fuel tank.
• Disconnect the vapor hoses at the rear of the fuel tank.
• If equipped, remove the fuel tank skid plate.
• Disconnect the vapor hose and the fuel hose(s) forward of the fuel tank.
• Position a suitable jack under the fuel tank, ensuring you do not support the tank directly beneath the fuel pump mounting area, as this can cause damage to the fuel pump assembly.
• Remove the fuel tank front and rear support straps and lower the front of the fuel tank by approximately 25 mm (1 inch).
• Remove the rear LH and RH sway bar bracket nuts and lower the sway bar.
• Remove the rear driveshaft.
• Loosen the clamp and disconnect the vent hose from the fuel tank vent spout.
• Disconnect the fuel pump electrical connector.
• Remove the fuel tank from the vehicle.

Once the fuel tank has been removed, you can access the fuel pump for replacement. Here are the steps to replace the fuel pump:

• Disconnect the quick-release fittings from the fuel pump.
• Remove the fuel pump lock ring. This may require a special tool from Ford.
• Carefully remove the fuel pump assembly, being cautious not to damage the fuel level sensor.
• Note the location of the fuel pump alignment tabs and remove the O-ring.
• Remove the fuel level sensor.

To install the new fuel pump, simply reverse the removal procedure. Ensure that you route the fuel vent hose and fuel tank pressure sensor correctly above the crossmember and brake cables.

The fuel pump costs between $140 and $360

The fuel pump is an external engine part that delivers fuel from the gas tank to the engine bay. It also pressurizes the fuel to between 30 and 45 psi, before the fuel injectors send the fuel into the cylinders to facilitate ignition.

If you are considering replacing the fuel pump yourself, it is important to note that working with the fuel system is dangerous and you should take all precautions to avoid starting a fire. It is recommended that you let a repair shop handle this job, unless you are very experienced in auto repair.

If you choose to replace the pump yourself, you will need to disconnect the battery, remove the fuel tank, disconnect the vapor hoses at the rear of the tank, and disconnect the fuel pump electrical connector. You will also need to remove the fuel pump lock ring, being careful not to damage the fuel level sensor. Finally, you can remove the fuel pump assembly and install the new one.

When replacing the fuel pump, it is recommended that you also replace the fuel filters at the same time.

The fuel pump pressurises fuel to between 30 and 45 psi

The fuel pump is a component used in liquid-fuelled engines to transfer the fuel from the fuel tank to the carburetor or fuel injectors. The fuel pump pressurises the fuel to ensure it is delivered correctly and in the right amount.

In fuel-injected petrol engines, an electric fuel pump is typically located inside the fuel tank. For older port injection and throttle-body injection systems, the "in-tank" fuel pump transports the fuel from the fuel tank to the engine, as well as pressurising the fuel to typically 40–60 psi (3–4 bar).

In the case of the 2003 Ford Expedition, the fuel pump delivers fuel at a pressure of between 30 and 45 psi. This is because the Ford Expedition has a fuel-injected petrol engine.

If you are replacing the fuel pump, it is important to ensure that the new pump can deliver the required pressure. Using the incorrect fuel pump can lead to excessive pressure and engine operating problems.

A failing fuel pump may cause the engine to sputter or stall

A failing fuel pump can cause the engine to sputter or stall unexpectedly during operation. This can happen because the fuel pump is not able to provide a steady flow of fuel, causing the engine to struggle to maintain a smooth operation. The engine may sputter or stall if the fuel pump cannot deliver the necessary amount of fuel to the engine consistently. This can be particularly noticeable when the fuel demand is high, such as during acceleration or when climbing uphill.

A degraded or aged pump motor may become overheated, subjecting the entire engine to excessive heat. If your car cuts off due to a failing fuel pump, don’t hesitate to seek immediate attention. Your safety and the health of your vehicle depend on it.

If the fuel pump is unable to deliver a constant stream of gas at higher speeds, your vehicle’s engine will sputter and threaten to stall. Engine sputtering, especially at higher speeds, might be caused by a weak fuel pump that’s not providing enough fuel to the engine.

A loud whining noise from the fuel tank area may indicate a failing fuel pump

If you hear this noise, it is important to get your Ford Expedition's fuel pump checked or replaced as soon as possible to prevent further damage and potential safety hazards. The process of replacing a fuel pump involves disconnecting the vehicle's battery, relieving the fuel system pressure, accessing the fuel pump, disconnecting the old fuel pump, and installing a new one.

It is worth noting that some people have found ways to replace the fuel pump without dropping the fuel tank. However, the process can be complex and may require specific tools.

• Release the fuel system pressure.
• Drain the fuel tank.
• Disconnect the vapor hoses at the rear of the fuel tank.
• Remove the fuel tank skid plate, if equipped.
• Disconnect the vapor hose and the fuel hose(s) forward of the fuel tank.
• Position a suitable jack under the fuel tank, being careful not to support it directly beneath the fuel pump mounting area to avoid damage.
• Note the routing of the fuel vent hose and remove the fuel tank front and rear support straps. Lower the front of the fuel tank slightly.
• Remove the rear sway bar bracket nuts and lower the sway bar.
• Remove the rear driveshaft.
• Loosen the clamp and disconnect the vent hose from the fuel tank vent spout.
• Disconnect the fuel pump electrical connector.
• Remove the fuel tank from the vehicle.
• To install the new fuel pump, follow the above steps in reverse, making sure to connect the electrical connector and all hoses before reinstalling the fuel tank.

Frequently asked questions