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How to Replace the Fuel Pump on a 1983 Mercury Cougar

All Mercurys produced in 1983 were equipped with a single electronic fuel pump rather than with the more traditional mechanical fuel pump. The fuel pump was installed inside the fuel tank rather than against the engine block. Although the pump was designed to last for several years, the pump will eventually need to be replaced. Fortunately, accessing and replacing the pump is fairly simple, although it may be a bit awkward working underneath the vehicle.

Tools Used: Hand pump, Gas-safe container, Jack, Jack stands, Socket wrench, Screwdriver, Brass punch, Hammer

Replace the Fuel Pump

Removing the Old Fuel Pump

Remove the fuel from the fuel tank by inserting the hose from a hand pump into the fuel tank through the gas cap opening and actuating the pump. Insert the pump's output hose into a container suitable for safely storing gasoline.

Raise the back of the car with a jack and support the rear end on jack stands.

Remove the bolts which secure the vent, fuel supply and fuel return lines to both sides of the vehicle's frame with a socket wrench.

Pull the wiring connection off the fuel pump.

Loosen the clamps which secure the vent, fuel supply and fuel return lines to the bottom of the fuel tank with a screwdriver, then pull the lines off the tank.

Support the weight of the fuel tank with the jack, then loosen and remove the bolts which secure the mounting straps to the bottom of the fuel tank with a socket wrench.

Lower the fuel tank out of the vehicle with the jack.

Position a brass punch against one side of the circular fuel pump retaining ring located at the bottom of the gas tank, then tap the punch with a hammer to rotate the ring in a counterclockwise direction until the ring detaches from the tank.

Slide the fuel pump out of the gas tank.

Installing the New Fuel Pump

Slide the new fuel pump into the gas tank.

Position the pump's retaining ring onto the bottom of the gas tank, then rotate the ring in a clockwise direction to secure the pump in place. Tighten the ring with the punch and hammer if necessary.

Raise the fuel tank into position from underneath the vehicle with the jack.

Install and tighten the bolts which secure the mounting straps to the bottom of the fuel tank with the socket wrench.

Press the vent, fuel supply and fuel return lines onto their respective fittings on the fuel tank, then tighten their clamps with a screwdriver.

Plug the fuel pump's wiring connection onto the fuel pump.

Install and tighten the bolts that secure the vent, fuel supply and fuel return lines to the vehicle's frame with the socket wrench.

Lower the vehicle to the ground with the jack.

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