Replacing Motorcraft Pfb-101 Fuel Pump: Step-By-Step Guide

The Motorcraft PFB-101 Fuel Pump is a direct-fit replacement for your vehicle's worn-out or malfunctioning fuel pump. It is designed to provide easy, no-hassle installation and restore proper fuel system functionality, ensuring your vehicle performs reliably, efficiently, and safely. This fuel pump is manufactured to OE quality standards and fits multiple makes and models. It is also backed by a two-year unlimited mileage warranty, offering peace of mind and confidence in its performance and durability.

Installation process

The Motorcraft PFB-101 Fuel Pump is designed as a direct-fit replacement for your vehicle's worn-out or malfunctioning fuel pump. Here is a step-by-step guide on how to install it:

• Prepare the Vehicle: Park your vehicle on a level surface and engage the parking brake. Make sure the engine is cool before starting work. Disconnect the negative battery terminal to prevent any accidental electrical shorts.
• Access the Fuel Pump: The fuel pump is usually located inside the fuel tank. Refer to your vehicle's repair manual to identify the exact location and the procedure to access the fuel pump. You may need to raise the vehicle, remove the fuel tank, or access it from the trunk or rear seat.
• Disconnect the Old Fuel Pump: Carefully disconnect the electrical connectors and fuel lines from the old fuel pump. Take note of the routing and orientation of the fuel lines and electrical connections for proper installation of the new fuel pump.
• Remove the Old Fuel Pump: Remove the mounting bolts or retaining clips holding the old fuel pump in place. Carefully lift out the old fuel pump from the fuel tank or its housing.
• Clean the Fuel Pump Housing: Before installing the new fuel pump, clean the fuel pump housing or mounting area to remove any debris or residue. This ensures that no contaminants enter the fuel system.
• Install the New Motorcraft PFB-101 Fuel Pump: Place the new fuel pump into the fuel tank or housing, ensuring it is securely seated and aligned correctly. Reattach the mounting bolts or retaining clips to secure the fuel pump in place.
• Reconnect the Fuel Lines and Electrical Connectors: Reconnect the fuel lines and electrical connectors to the new fuel pump, following the routing and orientation observed earlier. Ensure all connections are secure and tight to prevent fuel leaks or electrical issues.
• Reinstall the Fuel Tank (if removed): If you had to remove the fuel tank to access the fuel pump, carefully reinstall it following the reverse procedure of its removal. Ensure all fuel lines, hoses, and electrical connections are properly secured.
• Reconnect the Negative Battery Terminal: Reconnect the negative battery terminal that was previously disconnected.
• Start the Engine and Check for Leaks: Turn on the ignition and let the engine run for a few minutes. Check for any fuel leaks around the fuel pump and the fuel lines. Also, check the fuel pressure to ensure it is within the specified range for your vehicle.

Note: Always refer to your vehicle's repair manual or seek assistance from a qualified mechanic if you are unsure about any steps or procedures. Working on the fuel system can be dangerous, so ensure you take the necessary safety precautions.

Removing the old pump

To remove the old Motorcraft PFB-101 fuel pump, start by disconnecting the two fuel lines at the back and the two at the front. Then, unplug the two electrical connectors. You will need to unbolt the entire unit from the frame, using the appropriate tools. Take care when removing the unit, as there may be a brake line running underneath it.

Once the old pump is free, take note of the fuel line connectors, as they are different sizes and will only fit the correct fuel line. Label each connector and its corresponding fuel line to ensure proper installation of the new pump.

It is also important to wear eye protection during this process, as rust and debris may fall from the vehicle.

Finally, ensure that you have the correct connectors for the new pump. The newer replacement pumps do not have a heater, so you will need the two-connector harness.

Replacing with the new pump

Once you have removed the old fuel pump, you can begin to install the new Motorcraft PFB-101 fuel pump.

First, carefully move the new pump into place, ensuring it is positioned correctly and securely. You may need to refer to the vehicle's manual or a trusted mechanic for guidance on the specific placement of the pump. Next, bolt the new pump to the frame, using new nuts if possible, although you can reuse the old ones if necessary.

Make sure to reconnect the fuel lines, ensuring they are attached to the correct connectors. The fuel lines are different sizes, so each line will only fit one connector. Plug the wires back in, checking that they are securely connected.

Finally, if needed, install a new filter. The Motorcraft PFB-101 fuel pump may come with a new filter already installed, but it is always good to double-check.

With the new pump installed, you can now start the engine and check for any leaks or issues. It is important to ensure that the pump is functioning properly before driving the vehicle.

Fuel line connection

Fuel lines are prone to failure over time and are more complicated than older models due to the fuel injection systems used in modern vehicles. Fuel-injected vehicles use fuel line pressures of 45-60 PSI, while older carbureted vehicles use only 4-8 PSI.

Today's vehicles have a larger number of lines, a variety of fittings, and flex lines. Many now use nylon lines instead of steel, and in many cases, special tools are required to remove the fuel filter and fuel line-to-engine quick connectors.

Spring locks and nylon safety clips are common. The spring lock connector comes in various sizes and requires a tool to insert into the connector, lifting the spring over the flare to release the fitting.

Nylon lines tend to break near the fuel filter due to the twisting and force needed to remove them. A nylon repair tool is necessary to fix the line, and a repair kit is available at most auto parts stores. It includes two opposing blocks with multiple-sized holes, a gun to hold the blocks, and a nylon tubing cutter. The kit holds the lines while a tapered connector with three step-downs presses into the nylon fuel line.

Nylon fuel lines and connectors are available at auto parts stores, and the connectors come with enough pigtail for secure repairs.

Repair Procedure for Nylon Fuel Lines:

• Keep all sources of ignition away from the area to prevent accidental fires.
• Never use electric tools when working on a fuel line.
• Find a wood screw large enough to thread into the nylon fuel line when removed.
• Place a drain pan under the area.
• Use wire cutters or a small hacksaw to remove the section that needs replacement. Install the wood screw to prevent further draining.
• Take the removed piece of fuel line and purchase the correct-sized line or fitting, along with a tapered fuel line connector.
• Hold the replacement line in position and mark where to cut.
• Use the nylon line cutter to remove the line.
• Place the opposing ends of the fuel lines into the block's threaded side, allowing 1/4" to protrude.
• Place a small amount of oil on the tapered connector and insert it into one side of the fuel line.
• Squeeze the handle on the tool, bringing the blocks together, and align the connector with the opposing fuel line.
• Squeeze the handle until the connector is fully seated on all three steps in both ends of the fuel line. Remove the tool.

Repairing a Metal Fuel Line:

• You will need a short handheld tubing bender and a tubing cutter.
• Place a drip pan under the area to catch any fuel drips.
• To prevent constant dripping, use a small piece of rubber tubing with a block-off screw.
• Remove the broken fuel line using the tubing cutter. Make the cut as far back as necessary, leaving at least 3 inches of a straight line to install the compression fitting.
• Purchase the necessary length of fuel line and one compression fitting if replacing the line to the fuel filter. Purchase two compression fittings for a fuel line section, adding 6 inches to the line for good measure.
• Make any necessary bends for proper fitment.
• Hold the replacement line in place and cut an additional inch off the original line to account for the compression fitting.
• Separate the parts of the compression fitting.
• Place one perforated cap on the original line with the threads facing out.
• Install the ferrule (ring) over the line in front of the cap.
• Push the original fuel line with the ferrule and cap into the center section of the connector. Hold the connector and push the line until it is completely seated.
• Thread the cap onto the center section of the connector, keeping sufficient pressure on the fuel line to ensure it remains seated while tightening the cap.
• Install the cap and ferrule on the opposite end and tighten.
• Turn the key on and check for leaks.

Choosing the Right Fuel Line:

Fuel lines can be made from various materials, and metal lines are standard in most cars because they hold up better than any soft material. Metal lines are typically made from stainless steel, aluminum, or coated steel tubes. While metal is the best material, it can be challenging to fabricate.

Rubber fuel hose is easy to install and is typically connected using barbed fittings and fuel line hose clamps. It must be rated for fuel or meet SAE grades:

• SAE J30R7 is carburetor-rated and should only be used for limited runs up to 50 PSI.
• SAE J30R9 is fuel injection-rated and can handle up to 100 PSI.

Rubber hose has some drawbacks, including degradation when exposed to fuel, leakage of fuel vapors, and susceptibility to cuts and abrasions. For budget-friendly fuel line repairs, nylon tubing may be a better option.

Braided hose is rubber hose with a braided stainless or nylon exterior. While more durable than plain rubber, it still has issues with long-term durability and fuel vapors.

PTFE-lined hose is the best soft hose available and generally has a braided stainless or nylon exterior. The PTFE liner blocks fuel vapors and slows degradation but is less flexible and requires special fittings.

Testing and maintenance

Motorcraft PFB-101 fuel pumps are tested for optimum reliability and functionality. They are designed to meet OE quality standards and are made to provide years of reliable function and hassle-free service. Before shipping, the fuel pumps are 100% flow-tested to ensure consistent performance.

The Motorcraft PFB-101 fuel pump is a direct-fit replacement part that is easy to install. It is designed to restore the proper fuel system functionality needed to keep your vehicle performing reliably, efficiently, and safely.

The pump comes with a two-year unlimited-mileage warranty, with labor included and no commercial exceptions. The warranty covers any new Motorcraft part that is found to be defective in factory-supplied material or workmanship and will be repaired, replaced, or exchanged at Ford's discretion.

To ensure the longevity of your Motorcraft PFB-101 fuel pump, it is important to follow the recommended maintenance schedule and properly maintain your vehicle's fuel system. Regularly check for leaks, clogs, or damage to the pump and its components, and replace the fuel filter as recommended by the manufacturer.

Additionally, it is important to use the correct type and quality of fuel for your vehicle, as using fuel with a higher or lower octane rating than recommended can impact the performance and longevity of the fuel pump.

Frequently asked questions