Replacing Fuel Pump In 2001 Mercury Cougar: Step-By-Step Guide

If your 2001 Mercury Cougar is experiencing issues with its fuel pump, you may need to replace it. The fuel pump is located inside the fuel tank and can be accessed by removing the fuel tank and disconnecting the necessary hoses and electrical connections. This process requires careful handling of flammable fuel and can be complex, so it is recommended that you seek the help of a qualified mechanic. The cost of a fuel pump replacement for a 2001 Mercury Cougar typically includes $97 for parts and $119 for labor.

Remove fuel tank straps

To remove the fuel tank straps and drop the tank of your 2001 Mercury Cougar, follow these steps:

First, relieve the fuel system pressure and drain the fuel from the tank. Next, raise the vehicle on a hoist and remove the exhaust system as required. Place a safety support under the fuel tank.

Now, remove the bolts from the fuel tank support straps. Take care not to deform the fuel tank or the straps. Partially remove the fuel tank and disconnect the rear fuel supply return and vapor tubes at the push-connect fittings using a Fuel Line Disconnect Tool Set. Disconnect the electrical connector from the fuel pump module.

Finally, remove the fuel tank from the vehicle.

Relieve fuel system pressure

To relieve the fuel system pressure in a 2001 Mercury Cougar, follow these steps:

Firstly, remove the fuel tank straps. Next, drain the fuel from the fuel tank. Then, raise the vehicle using a hoist. After that, remove the exhaust system as required. Refer to Section 09-00 for further details on this step.

Now, disconnect the fuel tank to filler pipe hose and vent hoses connecting the fuel tank filler pipe. Disconnect one end of the vapor crossover hose at the rear over the driveshaft. Place a safety support under the fuel tank. Remove the bolts from the fuel tank support straps. Be careful not to deform the fuel tank or the fuel tank support straps.

Partially remove the fuel tank and disconnect the rear fuel supply return and vapor tubes at the push connect fittings using a Fuel Line Disconnect Tool Set. Finally, disconnect the electrical connector from the fuel pump module.

Drain fuel from the tank

To drain the fuel from the tank of a 2001 Mercury Cougar, follow these steps:

First, relieve the fuel system pressure as described under Fuel System Pressure Relief. This is an important safety step to prevent any accidental spillage or injury.

Next, raise the vehicle on a hoist or jack stands to gain access to the fuel tank. Place a suitable container underneath the tank to collect the drained fuel.

Locate the fuel tank drain plug or valve. This is usually at the bottom of the fuel tank. Before opening the drain, make sure the container is properly placed and has enough capacity to hold the drained fuel. Open the drain and allow the fuel to flow out.

Once the fuel has been completely drained, close the drain securely. It is important to properly dispose of the drained fuel in accordance with local regulations and environmental guidelines.

Now that the tank is empty, you can proceed with the next steps in accessing and replacing the fuel pump. This may involve lowering the fuel tank, disconnecting hoses and electrical connections, and removing the fuel pump module.

Remember to exercise extreme caution when working with flammable liquids like gasoline. Ensure proper ventilation and avoid any open flames or potential ignition sources. It is recommended to wear appropriate safety gear, including gloves and eye protection.

Disconnect fuel tank connections

Disconnecting the fuel tank connections is a crucial step when changing the fuel pump in a 2001 Mercury Cougar. Here is a detailed guide on how to do this:

First, relieve the fuel system pressure as described under Fuel System Pressure Relief. This is an important safety step to avoid any accidental spillage or injury. Next, drain the fuel from the fuel tank. You can refer to your car manual or seek expert advice for the correct procedure. Once the fuel is drained, raise the vehicle on a hoist.

Now, you need to access the fuel tank connections. To do this, remove the exhaust system as required. Refer to Section 09-00 for detailed instructions on exhaust system removal. With the exhaust system out of the way, you can access the connections for the rear fuel supply return and vapor tube (9S278) on top of the fuel tank. These connections are inaccessible with the fuel tank in its original position, so you will need to partially lower the fuel tank from the vehicle to disconnect them. Use a fuel line disconnect tool set, such as the T90T-9550-S, to disconnect the rear fuel supply return and vapor tubes at the push-connect fittings.

Additionally, you will need to disconnect the fuel tank to filler pipe hose (9047) and vent hoses connecting the fuel tank filler pipe (9034) to the fuel tank. You will also need to disconnect one end of the vapor crossover hose at the rear over the driveshaft (4602). These hoses and connections are crucial for the proper functioning of the fuel system and vapor management, so ensure that you are careful during this process.

Before lowering the fuel tank, remember to place a safety support under it to prevent any accidental damage.

Remove and replace the fuel pump

To remove and replace the fuel pump in a 2001 Mercury Cougar, follow these steps:

First, relieve the fuel system pressure and drain the fuel from the fuel tank. Raise the vehicle on a hoist if necessary. Remove the exhaust system as described in Section 09-00. Disconnect the fuel tank to filler pipe hose (9047) and vent hoses connecting the fuel tank filler pipe (9034) to the fuel tank. Disconnect one end of the vapor crossover hose at the rear over the driveshaft (4602).

Place a safety support under the fuel tank. Remove the bolts from the fuel tank support straps (9092), being careful not to deform the fuel tank or straps. Partially remove the fuel tank and disconnect the rear fuel supply return and vapor tubes at the push connect fittings using a Fuel Line Disconnect Tool Set T90T-9550-S. Disconnect the electrical connector from the fuel pump module.

Now you can remove the old fuel pump module from the fuel tank. Install the new fuel pump module, securing it with the retaining bracket and bolts. Reattach the electrical connector and fuel supply/return lines. Reinstall the fuel tank and exhaust system, ensuring all connections are secure.

Finally, refill the fuel tank and start the engine to test for leaks. Ensure the fuel pump is functioning properly and that there are no warning lights on the dashboard.

It is important to note that the fuel pump is located inside the fuel tank, so accessing it will require lowering the fuel tank from the vehicle. Always take proper safety precautions when working with fuel and electricity, and refer to a qualified mechanic if you are unsure about any steps.

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