how to fix a Ford Explorer Fifth Generation (2011-2019) that won't start after refueling

Ford Explorer Fifth Generation (2011-2019)

Error Codes

2-4 hours

Time

medium

Difficulty

high

Severity

3 min read

600 words

⚠️ Safety Warning

This issue requires immediate attention. If you are not experienced with automotive repairs, consult a professional mechanic. Working on critical systems can be dangerous.

Problem Statement

Learn how to diagnose and fix fuel system issues in Ford Explorer Fifth Generation (2011-2019). Step-by-step guide with symptoms, diagnostic steps, and repair instructions.

Affected Component

Fuel System

Estimated Time

2-4 hours

⚠️ Safety Warnings

Important safety information - read before proceeding

•Disconnect the battery before working on electrical systems.
•Allow the engine to cool before working on fuel system components.
•Work in a well-ventilated area to avoid inhaling fuel vapors.

Symptoms

•Engine cranks but does not start
•Fuel gauge may indicate full or fluctuating levels
•Check engine light may be illuminated
•Fuel odor around the vehicle
•Possible stalling shortly after starting
•Difficulty in starting after a prolonged period of sitting

Diagnostic Steps

1
Scan the vehicle's OBD-II system for any error codes related to fuel system issues.
2
Inspect the fuel pump fuse and relay for continuity and proper operation.
3
Check for fuel leaks around the fuel lines and connections.
4
Measure fuel pressure at the fuel rail using a fuel pressure gauge.
5
Inspect the fuel injectors for clogs or electrical issues.
6
Verify the operation of the fuel tank vent system for blockages.

Solution

💡 Expert Tip

For complex repairs like this, consider taking photos at each step. This helps if you need to reverse a step or consult with a mechanic. Also, keep all removed parts organized - you may need to reference them during reassembly.

Verification

After completing the repair, verify that the issue has been resolved:

✓Test the affected component to ensure it functions correctly
✓Check for any error codes or warning lights
✓Monitor the vehicle for a few days to ensure the issue does not recur

Prevention Tips

To prevent this issue from occurring again:

•Follow the manufacturer's recommended maintenance schedule
•Address warning signs early before they develop into major issues
•Use quality parts and fluids recommended for your vehicle
•Keep detailed records of all repairs and maintenance

Tools & Equipment Required

•OBD-II scanner
•Multimeter
•Socket set
•Screwdriver
•Fuel pressure gauge
•Fuel line disconnect tool
•Pliers

Parts Required

•Fuel pump relay
•Fuel pump
•Fuel filter (if necessary)
•Vent hoses or EVAP canister (if necessary)

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Diagnostic Steps

1
Scan the vehicle's OBD-II system for any error codes related to fuel system issues.
2
Inspect the fuel pump fuse and relay for continuity and proper operation.
3
Check for fuel leaks around the fuel lines and connections.
4
Measure fuel pressure at the fuel rail using a fuel pressure gauge.
5
Inspect the fuel injectors for clogs or electrical issues.
6
Verify the operation of the fuel tank vent system for blockages.

Solution

1. Preparation

Gather all necessary tools and parts.
Ensure the vehicle is parked on a flat surface and the engine is off.
Disconnect the battery to prevent any electrical issues during repairs.

2. Inspect and Replace Fuel Pump Relay

Sub-steps:
- Locate the fuel pump relay in the fuse box.
- Remove the relay and test it with a multimeter for continuity.
- If faulty, replace with a new relay.
Tools Required: Multimeter, replacement fuel pump relay

3. Check and Replace Fuel Pump

Sub-steps:
- Remove the fuel tank access cover.
- Disconnect the fuel lines and electrical connectors from the pump.
- Remove the mounting screws and take out the fuel pump.
- Install the new fuel pump, reconnect the lines and electrical connectors, and secure it with mounting screws.
Tools Required: Socket set, screwdriver, fuel line disconnect tool
Safety Warnings: Work in a well-ventilated area to avoid inhaling fuel vapors.

4. Test Fuel Pressure

Sub-steps:
- Connect a fuel pressure gauge to the fuel rail.
- Turn the ignition to the ON position (do not start the engine) to prime the fuel system.
- Check that the fuel pressure reading meets the manufacturer specifications (typically around 50-60 PSI).
- If pressure is low, further investigate fuel filter or injectors.
Tools Required: Fuel pressure gauge

5. Inspect Vent System

Sub-steps:
- Inspect the fuel tank vent hose for blockages or kinks.
- Check the EVAP canister for damage or clogs.
- Replace any damaged components as necessary.
Tools Required: Pliers, replacement hoses or canister if needed