Like many fuel-injected vehicles, the 2002 Ford Explorer has a high pressure fuel pump module mounted in the fuel tank to supply fuel to the fuel injection system. The modular design of this assembly prevents fuel sloshing, and keeps the pump motor submerged in fuel so it stays cool to minimize wear. Replacing the fuel pump is a project that can be completed by the average home mechanic in an afternoon.
Relieve the residual fuel pressure in the fuel lines by removing the 20-amp fuel pump fuse located in position 19 (marked on the fuse block) in the under-hood fuse block of the 2002 Explorer. Start the engine and allow it to run until it stalls indicating the fuel pressure is relieved. Turn the key to the "Off" position.
Push wheel chocks in front of, and behind, the front wheels. Lift the rear of the Explorer using a floor jack under the center of the differential and slide jack stands under both rear axle tubes. Lower the truck onto the stands, to support the vehicle's weight, for safety.
Unplug the electrical connector located near the front of the fuel tank by lifting the locking tab as you pull the two halves of the connector apart. Disconnect the fuel filler neck and vent hose from the fuel tank by loosening the hose clamps on the hoses using a screwdriver and then prying the hoses off the fuel tank.
Roll the floor jack under the fuel tank and place a wood block between the jack and the tank. Lift the tank up slightly and remove the 15-mm bolts that attach the tank straps to the frame of the car. Lower the tank down with the floor jack until you can reach the fuel lines on top of the tank.
Disconnect the fuel lines by disconnecting the the quick disconnect fittings using the fuel line disconnect tool. In the 2002 Explorer the fittings are located on the top of the fuel tank attached to the fuel pump assembly. Clip the tool around the metal portion of the line and push it into the fitting then pull the two halves of the line apart.
Lower the tank and slide it from under the Explorer. Rotate the lock ring that secures the fuel pump assembly to the tank using a screw driver and hammer until the spring loaded assembly pops up from the tank. Lift the assembly from the tank.
Slip the new fuel pump assembly into the tanks and secure it in place with the locking ring. Slide the tank under the vehicle and lift it into place using the floor jack and block of wood. Reconnect the fuel lines by pushing them onto the fuel pump assembly until they click into place and can not be pulled off without the disconnect tool.
Reinstall the tank straps, fuel filler neck, vent hose and electrical connector. Reinstall the fuel pump fuse into the fuse block. Turn the ignition key to the "RUN" position for two seconds and then turn it to the "Off" position. Cycle the ignition key in this manner several times to prime the fuel system. Start the engine and check for leaks.
Lift the Explorer off the jack stands using the floor jack. Remove the stands and lower the vehicle to the ground. Remove the wheel chocks and test drive the Explorer to verify it runs properly.
