Replacing The Fuel Pump In A 2003 Town Car

If you're looking to replace the fuel pump in your 2003 Lincoln Town Car, you're in for a complicated but manageable task. The fuel pump is located inside the fuel tank, and while you don't have to remove the tank completely, you will need to drain the fuel and lower it to access the pump. Here are the steps you can take to replace the fuel pump:

1. Depressurize the fuel system and remove the fuel from the tank.

2. Disconnect the supply line, return line fittings, vent line, and electrical connector.

3. Remove the fuel tank support straps and lower the tank carefully.

4. Disconnect the supply line, return line, and electrical connector from the fuel pump assembly.

5. Remove the old fuel pump and bracket assembly, and clean the mounting flange and surface.

6. Install a new fuel pump and bracket assembly, ensuring the filter is not damaged.

7. Secure the new fuel pump assembly and reconnect the lines and electrical connector.

8. Reinstall the fuel tank and tighten the straps.

9. Replace the fuel filter and check for leaks.

Remember to exercise caution when working with fuel, as gasoline is highly flammable and can irritate your skin. It is recommended to have a second person assist you with this task for safety.

Locate the suspension switch in the trunk and turn it off

To locate the suspension switch in the trunk of your 2003 Lincoln Town Car, open the trunk and look on the left side panel. The suspension switch should be a big black rocker switch. If you are unsure, try turning the switch on and off and observe whether the car's suspension rises and falls.

If you are still having trouble locating the suspension switch, you can try checking the right side of the passenger footwell. This is another common location for the suspension switch in Lincoln Town Cars.

Once you have located the suspension switch, simply turn it to the "off" position. This will ensure that the suspension is deactivated before you begin jacking or lifting your vehicle. It is important to turn off the suspension switch before lifting your car to avoid damaging the air suspension system.

Jack up the car and drain the gas tank

To replace the fuel pump in a 2003 Lincoln Town Car, you'll need to first drain the gas tank. Here's a step-by-step guide on how to do this safely and effectively:

Preparation:

• Disconnect the negative battery terminals to ensure safety and prevent any issues with sparks and fire while draining the fuel.
• Find a highly-ventilated place to work, away from any flammable materials or electronics that could potentially ignite.
• Prepare storage containers for the fuel. It's a good idea to have more containers than you think you'll need. The average fuel tank capacity is between 40 and 60 liters, but this can vary depending on the vehicle.

Jacking up the Car and Draining the Tank:

• Chock the front wheels of your Lincoln Town Car and use a jack to raise the vehicle. Make sure you have enough room to work underneath.
• Use jack stands to support the vehicle securely.
• Open the gas cap to release pressure before attempting to drain the fuel.
• Place a bucket or pan underneath the fuel tank to catch the drained fuel.
• Locate the fuel tank drain plug. This is usually found on the same side of the car as the fuel filler neck.
• Use a ratchet and socket to loosen and remove the drain plug. Fuel will start to flow freely into the bucket or pan.
• Have towels ready to clean up any spilled fuel.
• Close the gas cap slightly to slow down the flow of fuel if needed.
• Once the tank is empty, replace and tighten the drain plug.

Alternative Method:

If your Lincoln Town Car doesn't have a drain plug, you can drain the fuel tank by disconnecting the fuel supply line from the fuel pump to the engine. Turn the key on, and fuel will start to push out of the line for about 30 seconds. Repeat this process as needed until the tank is empty.

Always put safety first when working with fuel. Make sure to properly dispose of the drained fuel at a local hazardous waste disposal center. Do not pour it down the sink or into the environment, as it can cause pollution and contamination.

Unscrew the bolts from the bands and lower the tank

To replace the fuel pump in a 2003 Lincoln Town Car, you'll need to access the fuel tank. The fuel pump is located inside the fuel tank, so you'll need to remove the tank or access it from the side. Here's a step-by-step guide to unscrewing the bolts from the bands and lowering the tank:

• Unscrew the bolts from the bands: Using your ratchet, start by unscrewing the bolts that secure the fuel tank bands in place. There should be four bolts in total. As you unscrew these bolts, the gas tank will begin to drop, so be prepared to support the tank as it lowers.
• Support the tank: Place a jack or a tall cinder block under the fuel tank to hold it up while you continue to unscrew the bolts and lower the tank.
• Pivot the tank: The fuel tank in a Lincoln Town Car is oblong-shaped, so you'll need to pivot it back and forth gently to lower it carefully.
• Secure the tank on a stand: As the tank comes down, carefully guide it onto the stand (jack or cinder block). Ensure that the tank is stable and secure before proceeding.

Now that the tank is supported by the stand, you can continue with the next steps to replace the fuel pump. Remember to exercise caution when working with fuel, as gasoline is highly flammable and can irritate your skin.

Disconnect the fuel inlet line and remove the tank

To disconnect the fuel inlet line and remove the tank of your 2003 Lincoln Town Car, follow these steps:

First, relieve the fuel pressure by detaching the black, negative battery cable with a wrench and removing the fuel filler cap. Open the hood and remove the cover from the top of the engine using a ratchet, ratchet extension, and socket. Locate the Schrader valve near the end of the fuel rail and remove the cap. Wrap shop rags around the valve and depress the valve stem with a small screwdriver to release fuel pressure. Reinstall the valve cap.

Next, we'll move on to removing the fuel tank. Disable the air suspension by turning the switch off in the luggage compartment. Drain the fuel tank through the fuel filler pipe into an approved container using a hand siphon pump. Disconnect the filler pipe from the car body by unscrewing the mounting bolts under the filler lid with a ratchet, ratchet extension, and socket. Loosen the wheel lugs from the rear left wheel with a lug wrench and lift the wheel off the ground with a floor jack. Support your Town Car on a jack stand and remove the wheel and tire assembly.

Now we can disconnect the fuel inlet line. Unhook the vapor-recirculation tube connector from the hose leading to the tank by pressing the lock tabs on the connector fitting. Unscrew the filler-tube retainer bracket near the fuel tank using a ratchet and socket. Push the filler pipe into the tank to gain clearance, then rotate the pipe counterclockwise and remove it from the fuel tank. On some models, you may need to remove the tank strap first to access the filler pipe fully.

At this point, you can disconnect the fuel lines by pressing the lock tabs to release the fittings. Locate the vapor tube on the right side of the fuel tank and disconnect it from the tee, plastic connector. Follow the vapor tube to the canister tube and disconnect it by pressing the lock tabs.

Finally, support the fuel tank with the floor jack and release it by unscrewing the mounting nuts using a ratchet, ratchet extension, and socket. Lower the tank carefully, remove the studs, and take the tank out of the vehicle.

Now you can install a new fuel pump and reassemble everything following the steps in reverse order. Remember to exercise caution when working with fuel, as it is flammable and can irritate your skin.

Disconnect the lines from the cap and remove the fuel pump assembly

Disconnecting the lines from the cap and removing the fuel pump assembly is a crucial step in replacing the fuel pump in a 2003 Lincoln Town Car. Here's a detailed guide on how to approach this task:

Step 1: Prepare the Vehicle

Before beginning any work, ensure the vehicle is turned off and parked on a level surface. Engage the parking brake to prevent accidental movement.

Step 2: Locate the Fuel Tank

Identify the fuel tank, which is located at the rear of the vehicle. Place a jack or a tall cinder block under the fuel tank to support it during the removal process.

Step 3: Drain the Fuel Tank

Open the fuel tank by removing the plug, and drain the gasoline into an approved container. Exercise extreme caution when handling gasoline, as it is highly flammable and can cause skin irritation. Ensure there is adequate ventilation during this process.

Step 4: Lower the Fuel Tank

Locate the four bolts securing the fuel tank bands. Using a ratchet, begin unscrewing these bolts. As you do so, the fuel tank will start to lower. Carefully pivot the tank back and forth to assist in lowering it.

Step 5: Disconnect the Fuel Inlet Line

Identify the fuel inlet line, which connects to the top portion of the fuel tank and is secured by a hose clamp. Using the appropriate tool, loosen and remove the hose clamp. Once the clamp is removed, carefully slide the fuel inlet line off the connection.

Step 6: Remove the Fuel Tank

With the inlet line disconnected, you can now remove the fuel tank from the vehicle. Carefully lift and lower the tank, ensuring you do not damage any surrounding components. Place the tank on a flat surface or a suitable container to catch any remaining fuel.

Step 7: Disconnect Lines from the Cap

This is the critical step you've been building up to. Using a screwdriver and, if necessary, a hammer, carefully unscrew the cap that covers the fuel pump assembly. You might need to turn the assembly at an angle as you pull it out, as the fuel sending unit is attached. Be cautious not to damage any components during this process.

Step 8: Access the Fuel Pump

With the cap removed, you will now see the fuel pump and sending unit attached together on the assembly. Carefully detach the cap from the rest of the fuel pump assembly, being mindful of the o-ring, which will need to be replaced with a new one during reassembly.

Step 9: Clean and Reassemble

At this point, you can clean the inside of the fuel tank to remove any accumulated sediment. Use a suitable cleaning solution or the excess fuel, ensuring the tank is completely dry before reassembly. Once the tank is clean, you can begin the reassembly process, starting with placing a new o-ring on the threaded part of the tank and reinstalling the cap over the fuel pump assembly.

Remember to exercise caution and seek assistance if needed when performing these tasks, especially when handling gasoline and working underneath a vehicle.

Frequently asked questions