1991 1999 ford explorer chilton User Manual

							The fuel pressure relief valve (A) is located on the fuel supply manifold
Inertia Switch
GENERAL INFORMATION
This switch shuts off the fuel pump in the event of a collision. Once the switch has been tripped, it must be
reset manually in order to start the engine.
The inertia switch is located on the toe-board, to the right of the transmission hump, in the passenger-side
footwell.
RESETTING THE SWITCH Turn the ignition switch OFF.
1. 
Ensure that there is no fuel leaking in the engine compartment, along any of the lines or at the tank.
There should be no odor of fuel as well.
2. 
If no leakage and/or odor is apparent, reset the switch by pushing the reset button on the top of the
switch.
3. 
You may need to pull the carpet down and away from the instrument panel in order to access the
switch. HOW TO USE THIS BOOK
Relieving Fuel System Pressure 611 
						

							Fuel pump inertia switch and reset button location
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The Inertia Fuel Shutoff (IFS) switch-when an impact occurs, the ball breaks loose from the magnet and strikes the target plate which opens the electrical contacts
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612 RESETTING THE SWITCH 
						

							Cycle the ignition switch from the ONto OFFpositions several times, allowing five seconds at each
position, to build fuel pressure within the system.
4. 
Again, check the fuel system for leaks. There should be no odor of fuel as well.
5. 
If there is no leakage and/or odor of fuel, it is safe to operate the vehicle. However, it is recommended
that the entire system be checked by a professional, especially if the vehicle was in an accident severe
enough to trip the inertia switch.
6. 
Fuel Pump
REMOVAL & INSTALLATION
To gain access to the fuel pump, it is necessary to remove the fuel tank. Depressurize the fuel system and remove the fuel tank from the vehicle.
1. 
Remove any dirt that has accumulated around the fuel pump attaching flange, to prevent it from
entering the tank during service.
2. 
Turn the fuel pump locking ring counterclockwise using a locking ring removal tool and remove the
locking ring.
3. 
Remove the fuel pump and bracket assembly.
4. 
Remove the seal gasket and discard it.
5. 
To install: Put a light coating of heavy grease on a new seal ring to hold it in place during assembly. Install it in
fuel tank ring groove.
6.  HOW TO USE THIS BOOK
Fuel Pump 613 
						

							Fuel pump and sending unit used on the Regular Cab Ranger pick-up
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614 REMOVAL & INSTALLATION 
						

							Fuel pump and sending unit used on the Super Cab Ranger pick-up
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REMOVAL & INSTALLATION 615 
						

							Fuel pump and sending unit used on the Explorer and Mountaineer
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Insert the fuel pump assembly into the fuel tank, then secure it in place with the locking ring. Tighten
the ring until secure.
1. 
Install the tank in the vehicle.
2. 
Install a minimum of 10 gallons of fuel and check for leaks.
3. 
Install a pressure gauge on the throttle body valve and turn the ignition ONfor 3 seconds. Turn the
key OFF, then repeat the key cycle five to ten times until the pressure gauge shows at least 30 psi.
Reinspect for leaks at the fittings.
4. 
Remove the pressure gauge. Start the engine and check for fuel leaks.
5.  HOW TO USE THIS BOOK
616 REMOVAL & INSTALLATION 
						

							
TESTING
CAUTION
Fuel pressure must be relieved before attempting to disconnect any fuel lines.
The diagnostic pressure valve (Schrader valve) is located on the fuel supply manifold (rail). This valve
provides a convenient point for service personnel to monitor fuel pressure, release the system pressure prior to
maintenance, and to bleed out air which may become trapped in the system during pressure replacement. A
pressure gauge with an adapter is required to perform pressure tests.
Fuel pressure can be checked using an inexpensive pressure/vacuum gauge
If the pressure tap is not installed or an adapter is not available, use a T-fitting to install the pressure gauge
between the fuel filter line and the throttle body fuel inlet or fuel rail.
To test the fuel pump, follow the accompanying diagnostic charts. Testing fuel pressure requires the use of a
special pressure gauge (Ford Tool T20L-3314-B, Rotunda Fuel Pressure Testing Kit 014-00441, or
equivalent) that attaches to the diagnostic pressure tap fitting. To perform the fuel system test a scan tool is
necessary to access the different test modes.
Depressurize the fuel system before disconnecting any lines. HOW TO USE THIS BOOK
TESTING 617 
						

							Fuel pressure test chart-part 1
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618 TESTING 
						

							Fuel pressure test chart-part 2
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Fuel pressure test chart-part 3 Click to enlarge
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TESTING 619 
						

							
Throttle Body Assembly
REMOVAL & INSTALLATION
Exploded view of the 2.3L and 2.5L engine throttle body assembly Click to enlarge
Exploded view of the 2.9L engine throttle body assembly and related components Click to enlarge
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620 Throttle Body Assembly