How to Change a Fuel Pump on a 2002 Ford Taurusby Dan FerrellUpdated November 07, 2017
Items you will need
Hand siphon pump, if necessary
Fuel container, if necessary
2 jack stands
Special tool 310-D006 or equivalent
Slip joint pliers
New fuel pump module sealer
The fuel pump on your Ford Taurus is located inside the fuel tank. Since the pump is part of a module assembly, you will need a special tool to service the unit. However, planning ahead of time, choosing the right place to work and having the replacement parts ready will speed up your job and help you get your Taurus ready sooner than you thought possible.
Relieving the Fuel System Pressure
Park your Taurus in a well-ventilated area with a level surface and away from appliances with open flames such as dryers and water heaters.
Open the hood and remove the fuel pump relay from the fuse box.
Start the engine and allow it to idle until it stalls.
Crank the engine for five seconds to finish relieving the fuel system pressure.
Turn the ignition key to the "Off" position.
Disconnect the negative (black) battery cable using a wrench.
Removing the Fuel Pump
Remove the fuel tank filler cap.
Drain the fuel from the fuel tank, if necessary, down to 1/4 tank or less. Use a hand siphon pump and a suitable container.
Raise the rear of your Taurus using a floor jack and support it on two jack stands.
Chock the front wheels.
Disconnect the three quick-connect couplings from the tubes at the tank by hand. If necessary, label each connector for easy reassembly.
Unplug the fuel pump electrical connector.
Disconnect the fuel filter inlet tube from the filter by hand.
Support the fuel tank with the floor jack. Place a wooden block between the tank and floor jack to prevent damage to the tank.
Unfasten the two fuel tank support straps using a ratchet, ratchet extension and socket.
Carefully lower the fuel tank.
Clean the top of the fuel pump module using a wire brush and rag to prevent dirt and debris from falling into the fuel tank after you remove the pump module.
Unscrew the fuel pump module retaining ring using tool number 310-D006 or a suitable retaining ring remover.
Turn the fuel pump module counterclockwise by hand to disengage the module from its mounting flange. Then, carefully lift and remove the module from the tank. Discard the fuel pump module sealer.
Installing the Fuel Pump
Remove the old fuel pump from the module using slip joint pliers and a screwdriver.
Install the new fuel pump on the module using the slip joint pliers and screwdriver.
Install a new fuel pump module sealer and carefully insert the fuel pump module in the tank.
Turn the fuel pump module clockwise until it hits the stops at the mounting flange.
Screw in the fuel pump module retaining ring using tool number 310-D006 or a suitable retaining ring remover.
Carefully lift the fuel tank into position.
Fasten the two fuel tank support straps using the ratchet, ratchet extension and socket.
Remove the floor jack from under the vehicle.
Connect the fuel filter inlet tube to the filter by hand.
Plug in the fuel pump electrical connector.
Connect the three quick connect couplings to the tubes at the tank.
Lower the vehicle.
Remove the chokes from the front wheels.
Refill the fuel tank, replace the fuel filler cap and fuel pump relay.
Connect the negative (black) battery cable using the wrench.
Turn the ignition key to the "On" position to pressurize the fuel system.
Check for leaks at the fuel tank.
Turn off the ignition key.
If you do not have access to the special tools needed for this job, visit your local auto parts store. Many auto parts outlets have special tools available for rent.
- "Ford Taurus & Mercury Sable 1996 thru 2005 (Hayne's Automotive Repair Manual)"; Ken Layne and John H. Haynes; 2006
Since 2003 Dan Ferrell has contributed general and consumer-oriented news to television and the Web. His work has appeared in Texas, New Mexico and Miami and on various websites. Ferrell is a certified automation and control technician from the Advanced Technology Center in El Paso, Texas.