Q: How to Diagnose and Replace a Fuel Pump and Fuel System Components on 2001 Ford Excursion?
A: When working on fuel, after having relive fuel pressure, It is best to cover with a shop towel any fuel connection that is to be unbolted in order to soak any dripping fuel. In case the fuel pump is not getting the right voltage, it is advisable to have a check on the inertia switch which is an electrical gadget in the fuel pump circuit. The fuel pump relay is a control and power kind and has primary and secondary voltage circuits; while the primary power circuit is controlled by the PCM, the secondary power circuit has direct connection with battery voltage on the ignition switched. When the ignition switch is ON, the PCM grounds the relay for one second and while cranking grounds the relay as long as it gets a reference signal from the camshaft position sensor; otherwise, the fuel pump will shut off after two or three seconds. If there are worries and doubts about inadequate delivery of fuel, a driver should check battery charge, fuel pump fuse, fuel filter for obstruction and fuel line for traces of leakage. For checking the efficiency of the fuel pump, put the vehicles gear in the Park or Neutral, apply the handbrake then have the assistant switch the ignition on while you put your ears close to the fuel pump listening for a whining sound for a couple of seconds. If the pump didn't turn on, look for ignition fuse, and the fuel pump relay. If the relays are good but the pump does not run, check the circuit associated with the fuel pump and if it is faulty replace the fuel pump. During a fuel pressure test, one needs a gauge used in measuring high fuel pressures; this must be connected at the fuel pump as well as the inlet line as the fuel system pressure is released. When all the accessories are off and the ignition key is on, allow the fuel pump to pressurize the system momentarily, then take the gauge reading. If the pressure is lesser than the prescribed pressure level, then there can be some obstruction in fuel line or wiring. If the pressure is higher than specified, there may be some restrictions to the line to the fuel filter/water separator. High fuel pump pressure means that there could be problem with the return lines, the pressure regulator, the fuel pump or the filter assembly and therefore should be diagnosed by a professional mechanic. When the model has FCM, drain the fuel system pressure, then disconnect the negative terminal of the battery, lift the vehicle, disconnect the fuel pump connector, and use special tools to disconnect the fuel lines. Any brake line of interference must be unclipped, fuel pump or module nuts be removed and correct module to be applied on 6.4L in order not to caused harm. And, at last, installation covers the process of removal.