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How to Replace the Fuel Pump on a 1991 Cougar

The Mercury Cougar is a model of car manufactured by the Lincoln-Mercury division of Ford Motor Company. The 1991 Mercury Cougar is a full-size coupe that belongs to the seventh generation of these vehicles. It may have a six-cylinder 3.8L engine or an eight-cylinder 5.0L engine. The fuel pump in a 1991 Mercury Cougar attaches to the fuel tank, so replacing the fuel pump requires you to remove the fuel tank.

Instructions

1

Disconnect the cable from the negative terminal on the battery with a socket wrench. Loosen the cap on the fuel tank and remove the cap for the fuel pressure relief valve on the fuel rail. Connect fuel pressure gauge T80L-9974-A to the relief valve and place its drain hose in a gasoline container. Open the pressure gauge and drain the fuel from the fuel system into the container. Disconnect the fuel pressure gauge.

2

Raise the vehicle and support its rear end with jack stands. Siphon as much fuel from the fuel tank as possible and disconnect the filler hose from the fuel tank. Remove the exhaust pipe and exhaust shields from the fuel tank. Place a floor jack under the fuel tank and place a plank of wood on top of the fuel tank. Disconnect the nuts for the retaining strap on the fuel tank and lower the fuel tank slightly so you can disconnect the fuel lines electrical wiring from the fuel tank. Remove the air deflector from the retaining straps of the fuel tank. Lower the fuel tank and remove it from the vehicle.

3

Clean the area around the retaining flange for the fuel pump on the fuel tank. Turn the locking ring for the fuel pump counterclockwise and detach the locking ring. Disconnect the fuel pump and bracket from the fuel tank and discard the seal ring.

4

Clean the mounting flange for the fuel pump and the groove for the seal ring on the fuel tank. Apply a thin layer of grease to the new seal ring and place the seal ring into the groove on the fuel tank. Connect the new fuel pump and bracket to the fuel tank without damaging the fuel filter. Align the keys on the fuel pump with the holes on the mounting bracket. Install the locking ring to the fuel pump so that the locking tabs on the locking ring are under the ring tabs on the fuel tank. Turn the locking ring clockwise until it reaches the limit of its travel.

5

Connect the fuel tank to the vehicle and lower the vehicle. Put at least 10 gallons of fuel in the fuel tank. Install a fuel pressure gauge on the relief valve and connect the negative battery cable with a socket wrench. Turn the ignition on for three seconds at a time until the fuel pressure reaches 35 psi. Remove the pressure gauge and cover the relief valve with the cap. Start the engine and check for fuel leaks.