1. Safety First:
* Disconnect the battery negative terminal. This is crucial to prevent sparks that could ignite fuel vapors.
* Ventilate the area. Work in a well-ventilated space to avoid inhaling fuel fumes.
* Wear safety glasses and gloves.
2. Preparation:
* Gather tools: You'll need jack stands, a jack, socket wrenches (various sizes), fuel line disconnect tools, possibly a fuel pump removal tool, and potentially a torque wrench.
* Locate the fuel tank: It's generally located under the rear of the vehicle.
* Empty the fuel tank as much as possible. This greatly reduces the weight and risk of spillage. You can siphon some out, but it's safest to nearly empty it.
3. Dropping the Fuel Tank:
* Secure the vehicle: Jack up the rear of the vehicle securely using jack stands. Never work under a vehicle supported only by a jack.
* Locate the fuel lines and electrical connectors: These are usually attached to the top or side of the tank.
* Disconnect the fuel lines: Use the appropriate disconnect tools to carefully separate the fuel lines. Have rags ready to soak up any spilled fuel. Be absolutely certain to relieve any pressure in the fuel lines before disconnecting them. Consult a repair manual for the correct procedure to avoid injury.
* Disconnect the electrical connector: Unplug the electrical connector to the fuel pump.
* Disconnect the fuel tank straps or supports: These usually involve bolts or clamps.
* Carefully lower the fuel tank: You may need to support the tank with straps or a helper to prevent damage.
4. Accessing the Fuel Pump:
* Once the tank is lowered sufficiently, you should be able to access the fuel pump assembly on top of the tank. This usually involves removing a cover or access plate. Your repair manual will show you exactly what to expect.
* Remove the fuel pump: This often involves unbolting the pump assembly and potentially using a special fuel pump removal tool.
5. Reassembly:
* Reverse the removal process to reassemble everything. Be meticulous in ensuring all connections are tight and secure.
* Double-check all fuel lines and electrical connectors.
* Fill the tank with fuel.
* Start the car and check for leaks.
Disclaimer: This is a general overview. Improperly working on a fuel system can be dangerous. If you are not comfortable performing this repair, it's best to take your vehicle to a qualified mechanic. Always refer to a repair manual specific to your Ford Falcon EL for precise instructions and safety precautions.
