2002 Mercury Cougar
NOTE: Fuel feed line connectors are White or are identified by a White band. Fuel return line connectors are Red or are identified by a Red band.
Removal & Installation
1. Release fuel pressure. Disconnect negative battery cable. Remove rear seat cushion. Remove rubber grommet from floor pan. Clean area to prevent contamination in fuel tank. Disconnect fuel pump module connector. On vehicles without returnless fuel systems, disconnect fuel feed and return lines from fuel pump module by squeezing tabs on fuel lines together and carefully pulling fuel lines from fuel pump module. On vehicles with returnless fuel systems, disconnect fuel feed line from fuel pump module by squeezing tabs on fuel lines together and carefully pulling fuel lines from fuel pump module.
2. On all vehicles, raise and support vehicle. Disconnect fuel filter outlet connector. Support exhaust system. Detach exhaust hanger insulators. Remove center exhaust heat shield. Detach stabilizer bar clamps and links. Support fuel tank. Remove fuel tank support strap bolts. Partially lower fuel tank. Remove stabilizer bar and fuel tank support straps. Disconnect fuel filler neck from fuel tank. Disconnect fuel vapor recirculation hose. Disconnect onboard refueling vapor recovery refueling hose (if equipped). Remove fuel tank.
3. Using Fuel Tank Sender Wrench (310-065A on returnless system, 310-065 on without returnless system), turn retainer ring counterclockwise and remove retainer ring. Remove fuel pump module. Cover fuel tank opening. Remove and discard "O" ring.
4. Ensure fuel pump and mounting surface is clean. Lubricate NEW "O" ring with suitable grease. Carefully install fuel pump module into fuel tank. Using fuel tank sender wrench, install retainer ring. To complete installation, reverse removal procedure. Pressurize fuel system and check for leaks.
Monday, March 23rd, 2009 AT 7:38 PM