Replacing The Fuel Pump In A '99 Taurus: Step-By-Step Guide

Replacing the fuel pump on a 1999 Ford Taurus can be a challenging task. Some people choose to cut an access hole in the top of the fuel tank, while others prefer to drop the tank and replace the pump from underneath. There are risks associated with both methods, and it's important to take precautions to avoid sparks and explosions when working with fuel. Online forums provide a wealth of advice and tutorials on this topic, with some users recommending specific videos and websites that offer step-by-step guides for a successful fuel pump replacement in a 1999 Taurus.

Cutting an access hole in the fuel tank

I was able to find some information on cutting an access hole in the fuel tank of a 1999 Taurus, but it is important to note that multiple sources advise against this method. Instead, they recommend dropping the tank from underneath the car and then removing the pump.

> I did this on my daughter's '99 Taurus about a year ago. There are several places on the Web that show pictures on where to cut. BUT, after all was said and done, I think it's harder than just dropping the tank and doing it the right way. There's almost no clearance between the floor and the tank and hoses, so you have to be extremely careful when cutting the floor. And it's harder to get the pump out because you can't reach and remove the wires and hoses from the top of the tank. When covering the hole back up, you have to make sure that the patch is flame-resistant, and getting the sheet metal patch to fit the contours of the floor isn't easy. I ended up using fire-proofing caulk to seal up the gaps.

The user also provided the following links for reference:

• Http://www.taurusclub.com/forum/98-solutions-common-problems-how-articles/124394-g3-gas-tank-fuel-pump-r-r.html
• Http://www.shoforum.com/showthread.php?t=59135
• Http://www.shoforum.com/showthread.php?t=86180

Another user on the same forum provided the following advice:

> Check this link out: Another Fuel Pump replacement (hole cut method) thread - SHOForum. Be careful because the fumes can fill a car pretty fast and a small spark from a door switch or similar could toast you.

This user also shared a link for reference:

Http://www.shoforum.com/showthread.php?t=86180

As you can see, this method involves significant risks and challenges, so it is essential to proceed with caution and carefully consider all alternatives before proceeding.

Disconnecting the fuel lines

Before you begin, it's important to relieve the pressure in the fuel system and disconnect the negative battery terminal to avoid any accidental sparks. It's also crucial to work in a well-ventilated area to avoid inhaling fumes. Now, let's get started:

Accessing the Fuel Lines

Locate the fuel lines at the rear of the fuel filter. These lines run from the fuel tank to the engine, supplying fuel to the vehicle. You will need to carefully loosen and detach these lines without damaging the connectors or the lines themselves.

Special Tools for the Job

It's recommended to use specialised tools for fuel line disconnection, such as fuel line disconnect tools or quick-disconnect tools. These tools are designed to safely release the lines without damage. Plastic disconnect tools might be ineffective and frustrating to use, so consider investing in quality tools to make the job easier.

Detaching the Fuel Lines

Using the appropriate tool, carefully insert it into the fuel line connector. Firmly but gently twist or pull the tool to release the line. Be cautious not to use excessive force, as it may damage the connector or the line. Work slowly and patiently, as fuel lines can be delicate.

Handling the Fuel Lines

Once the fuel lines are disconnected, carefully move them out of the way. You may need to wiggle them through tight spaces, being mindful not to kink or damage the lines. Place the lines in a safe area where they won't be stepped on or accidentally pinched. If there are multiple lines, keep them organised to avoid confusion during reassembly.

Final Checks

Before proceeding with the fuel pump replacement, double-check that all fuel lines are securely disconnected and safely moved aside. Ensure there are no leaks or drips from the lines, as this could pose a safety hazard. It's also important to inspect the lines for any signs of damage or wear, replacing them if necessary.

Remember to work cautiously and patiently when dealing with fuel lines, as they play a critical role in your vehicle's performance and safety. Taking your time and using the right tools will help ensure a successful and safe fuel pump replacement on your 1999 Taurus.

Dropping the tank

Before starting, ensure you have the necessary tools and safety equipment, including eye protection, gloves, and a jack to lift the car. Begin by parking the car on a level surface, engaging the parking brake, and chocking the wheels for added safety. Then, locate the fuel tank and identify the fuel lines, electrical connectors, and tank straps. It is important to familiarise yourself with the fuel system layout before proceeding.

Next, you will need to disconnect the fuel lines and electrical connectors. This step requires caution as it involves handling flammable liquids and delicate connections. Make sure to relieve the fuel system pressure and carefully detach the fuel lines, ensuring no sparks occur during this process. Collect any spilled fuel with a suitable absorbent material. Once the fuel lines are disconnected, label and disconnect the electrical connectors as well.

After the lines and connectors are safely detached, you can proceed to remove the tank straps. These straps hold the fuel tank in place, so removing them will allow you to lower the tank. Depending on the condition of the straps and bolts, you may need to use an impact tool to loosen any rusty or stubborn bolts. Be cautious when handling rusty components to avoid injury.

With the tank straps removed, you are now ready to lower the fuel tank. This step may require an extra pair of hands, as the tank can be heavy and cumbersome. Carefully lower the tank, ensuring it doesn't get caught on any nearby components. Place the tank on a secure stand or jack once it's lowered, making sure it is stable and secure.

Finally, inspect the tank for any signs of damage or corrosion. Pay close attention to the fuel lines and connectors, ensuring they are intact and properly seated. If you notice any issues, address them before reinstalling the tank. Remember to work cautiously and refer to repair manuals or seek professional guidance if needed.

Replacing the fuel pump

The fuel pump on a 1999 Ford Taurus is located inside the fuel tank. There are two methods for replacing it: cutting an access hole in the top of the fuel tank or dropping the tank.

Cutting an Access Hole

This method involves cutting a hole in the top of the fuel tank to access the fuel pump. However, it is important to note that creating a clean cut without damaging any lines or connectors can be challenging. Additionally, the fumes from the fuel can quickly fill the car, creating a safety hazard. Therefore, this method is not recommended unless you have prior experience and the necessary tools.

Dropping the Tank

This method involves removing the fuel tank from the car to access the fuel pump. Here are the steps to replace the fuel pump using this method:

• Remove the seat bottom and seat back from the car.
• Disconnect the electrical connector and fuel line connector before dropping the tank.
• Carefully disconnect the other lines and locking ring.
• Lower the fuel tank and replace the fuel pump.
• Reattach the fuel tank and reconnect all the lines and connectors.

By following these steps, you can successfully replace the fuel pump on your 1999 Taurus. It is recommended to refer to a repair manual or seek assistance from a qualified mechanic if you are unsure about any part of the process.

Reattaching the fuel tank

To reattach the fuel tank of your 1999 Taurus, you will need to first ensure that the fuel pump has been installed correctly and is functioning properly.

Next, carefully lift the fuel tank back into position, ensuring that all the lines and connectors are properly aligned and secured. Pay close attention to the fuel lines and electrical connectors, making sure they are correctly attached and free of any leaks.

Once the tank is in place, you can begin to secure it by reattaching the straps that hold it in place. Use new straps if the old ones are rusty or damaged. Tighten the bolts securely, but be careful not to over-tighten, as this can strip the threads or damage the tank.

Finally, reconnect the negative battery terminal and turn on the ignition to ensure the fuel pump is working. If the pump is functioning correctly, you can then lower the vehicle and tighten any remaining bolts or fasteners.

It is important to work cautiously and avoid creating any sparks when working with fuel lines, as this can be extremely dangerous. Always refer to a professional mechanic's advice or a detailed video tutorial if you are unsure about any steps.

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