How do you replace fuel pump in Ford Taurus 2002?

Answer 1

This repair is not a quick or easy one. The less fuel in the tank the easier it will be. I wouldn't recommend even attempting this repair with more than 1/4 of a tank of fuel, and you really need a lift to make this repair, especially if there is any weight to the tank whatsoever. And always perform fuel related repairs in a well ventilated area.

You can buy just the pump, but I would recommend going ahead and replacing the entire assembly. The cost is $220-$260 for Carter or Airtex brands.

1. Disconnect the cable from the negative battery post.

1.1 Remove the fuel relay and start motor and let run until it stalls, this step relieves the gas pressure.

2. Locate the fill tube (hard tube attached at the rear of the tank which goes to the gas cap) and remove the hose clamp at the end of the fill tube. Do not remove the clamp at the tank.

2.1 When removing the hose from the fill tube, place a 1" PVC cap into the gas tank side of the fill tube hose and clamp down using the existing clamp to eliminate the chance of spillage.

3. DO NOT PERFORM THIS STEP WITHOUT HAVING THE TANK SUPPORTED! The tank is attached by two metal straps which are bolted at the rear of the tank. When you support the tank, do not obstruct the straps, they will need to fall freely when you remove them. The straps are attached by one bolt each at the rear of the tank. Remove the bolts and let the straps fall away from the tank. IT IS EXTREMELY IMPORTANT THAT YOU DO NOT BEND THE STRAPS! They must retain their shape to fit back on the tank correctly.

3.1 If on the ground use a stack of 2X4's for tank supports and remove individual 2X4's as needed to lower the tank, it also helps giving clearance for the floor jack.

4. Lower the tank enough so that you can reach the top of the tank. Disconnect the plugs (2 of them). Take a look at the new pump to get an idea of how to disconnect the plugs if you need to.

5. Remove the sending unit sensor and vent tube (both should have blue caps). The smaller of the two will pop out with a little wiggling, but be careful to not break the lip. The larger of the two has to be rotated 90 degrees to be removed.

6. Remove the fuel line from the pump by pressing the button on the side of the coupling and the line should simply slide off. The tank should be completely free at this point.

6.1 Have something to catch the gas when removing this tube, it will leak gas out.

7. Remove the tank. Plug up any open holes in the tank to prevent trash from getting in the fuel.

7.1 Carefully clean the area around the locking rim prior to removing the ring to prevent junk getting into the tank.

8. Remove the locking ring. This is done by placing a screwdriver against the raised parts of the ring and tapping the screwdriver until the ring is free.

8.1 There is a tool for removing the locking ring, but I also used a screwdriver, but use extreme caution when doing this step, if possible wrap the tip of the screwdriver with a rag or other means to prevent sparks.

9. Press down on the pump assembly and rotate counter-clockwise very slightly until the assembly is free. It is spring-loaded so it should be very obvious when it is free. Remove the old assembly from the tank.

9.1 The old pump will leak out a lot of gas, drain or place in container.

10. Now would be a good time to remove any excess gas from the tank if you are not using a lift. The tank has to go back in a fairly precarious position so the lighter it is, the easier it will be to maneuver.

11. Remove the old seal and place the new one on the tank.

12. Place the new pump assembly in the tank. Press down and rotate the assembly until it locks in. Replace and tighten the locking ring.

13. Now it is time to replace and reconnect everything in the opposite order you disconnected them in. If the tank is in the correct position and there is nothing obstructing it (the plugs tend to get caught between the tank and the body which prevents the tank from seating correctly) then the straps should fit back easily.

14. Once you are sure everything has been reconnected (and don't forget the fill tube hose) put at least 10 gallons of gas in the tank before attempting to start the car.

15. Reconnect the battery post and start the car.

15.1. This job took about 3 hours my first time , including a stubborn gas strap bolt, and it cured my intermittent starting problem.

GOOD LUCK!!!