1999 cougar 2.5 replacing fuel pump. there are two lines attached to the top of the fuel pump housing, one is pressure, one is a return line. I can not get either of these line out of the fuel pump housing. there is a small collar going around the fuel lines where they enter the fuel pump housing. I released these collars, collars came up 1/8 to 1/4" then tried to pull twist lines from housing. return line came up 1/4" acts like it is frozen. checked fuel line under the collar and no obvious way to release line. pulled pump housing up 3" or so looked at bottom of housing where fuel lines enter, no obvious release for fuel lines. production date of car is 5/98. there are two fuel pumps for this car 5-25-99 is the cut off date for the fuel pumps. this is a 5/98 car two lines on top of housing, after 5/25/99 one line on top of fuel pump housing. appreciate any help dave this pump is in contour,mistique,madza mpv with the 2.5
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first check the red wire going to the wire clip at top of tank if it shows as hot then either the float is sticking or the sending unit is bad on the pump. if its bad you half to replace the fuel pump or if hot line is not hot then check the fuse box under the hood for blown fuse.
NOTE: The connections for the rear fuel supply return and vapor tube (9S278) to the fuel pump module are on top of the fuel tank and are inaccessible. They must be disconnected with the fuel tank partially lowered from the vehicle.
Disconnect fuel tank to filler pipe hose (9047) and vent hoses connecting the fuel tank filler pipe (9034) to 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). Take care not to deform the fuel tank or fuel tank support straps. Fuel tank capacity and/or fuel pick-up may be adversely affected.
Partially remove the fuel tank and disconnect the rear fuel supply return and vapor tubes at push connect fittings using Fuel Line Disconnect Tool Set T90T-9550-S. Disconnect electrical connector from the fuel pump module.
The Cougar uses the same platform as the Contour so it should be like it is on my Contour. Remove the rear seat bottom and you'll see a cover in the floor. Remove that cover and you'll be able to see the top of the fuel tank. You'll need to remove the lines coming out of the top and use a punch with a hammer to rotate that locking ring. Once you remove the ring you can pull the pump module out of the tank. Be careful not to bend the fuel level float. You'll be able to see how to get to the pump once the module is out. Just take the cover off and put the new pump in the module and re-install.
ok your cut off switch is under the glove box in the passenger footwell in the UK version, and mine did not have any further relay until the wiring hit the fuel pump itself, i had been told it was behind a panel in the back under the rear passenger windows, but having removed the entire inner trim of the rear of the car could find no relay at all. my problem was not relay in the end but a dead fuel pumpconfirmed by checking that i9 was getting voltage delivered to the pins of the pump plug when ket switch in position 2 as that is when the pump primes the engine
just finished one on my 99 cougar... remove the back seat, take out the rubber ring that has the fuel pump wires running through it. on the end of the wires is a clip that has to be removed before you can unplug it... it is metal... you just pull straight out to the side and it will come out... then remove the plug from top of fuel pump.... then feel directly to the right is a nother plug that has to be unplugged.... then with a long screwdriver (flat head) and a hammer knock the keeper ring clock wise to get it out from under the tabs.... slide the rings down the fuel lines... NOTE: THESE LINES ARE NOT TO BE REMOVED..... Pick fuel pump housing up out of tank and remove the pump, and replace with new one.... you may have to drop the fuel tank a little to pick it up out of tank... that's easy too... crawl up under it make sure it is on jack stands and the emergency brake pulled, and in park.. chalk the front wheels just too make sure it doesn't move.. then on the front of the tank there is two bolts one on each side.. remove them and tank will drop down enough to do job.... hope this helps
Easy enough fix to do yourself. There are 2 bolts that hold the fuel pump onto the engine. Remove and plug the fuel lines. Remove the 2 bolts holding the pump to the engine. Remove pump and pull towards you to clear the engine and remove. Remove the fittings to replace them on new pump. Match your new pump to your old pump and make sure the fittings are in the same locale. Replace the rubber hoses. Attach the gasket to the pump with adhesive. Slide the pump into place making sure the actuator arm is under the eccentric. Replace the bolts, hook up the fuel lines, and test. Make sure you have no leaks.
dziglar; make sure the metal lines are not cross-threaded, or over tight to crack housing.
Hope this helps; Thanks and please rate me high;