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#4051574 - 03/11/20 02:08 AM Fuel pump replacement issue on a 2002 GM
lmrogp Offline
Member

Registered: 01/02/09
Posts: 215
Loc: Sin City
Started doing a fuel pump replacement on my 2002 GM and immediately ran into an issue that I have not seen discussed before. Or maybe I'm missing something obvious? I'm talking about the easier of the two electrical connectors, the one that is accessible from the trunk. I got it disconnected without a problem.



But I cannot get it down from where it sits. The connector does not fit through the space between the trunk and the large black spring support piece that spans the width of the car.



If I could get it through that space, it would easily come down by the fuel lines. Am I missing something obvious here? Don't see how dropping the tank would help, as it would not have any effect on the space the connector needs to get through.



Speaking of dropping the tank, does my tank look too rusty for this job? First time I've done one of these, so I'm concerned about how good a seal I will get with the new pump. Maybe I should replace the tank as well?

_________________________
2009 Ford Crown Victoria Police Interceptor
Silver Birch Metallic, SAP, 118k, 867h, 3.27, Dual Exhaust, Mustang Wheels, LTC Jump Seat, OEM RKE Retrofit, BH1976 Headlight Relay Harness, Engine Compartment Light

2002 Mercury Grand Marquis GS
Spruce Green Metallic, 201k, 3.73, ETE Reman Transmission, DRP Tune, Dual Exhaust, HPP Wheels, Bilstein Shocks, VDO Tach, Compass Mirror, Factory AM/FM/CD Player

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#4051614 - 03/11/20 07:42 AM Re: Fuel pump replacement issue on a 2002 GM [Re: lmrogp]
Old_Guy_Stu Offline

Climber

Registered: 04/28/19
Posts: 822
Loc: Cleveland, OH
You lucky SOB, you can get to the pump without dropping the tank first!

That tank does look a bit nasty, but if it's not leaking now it won't leak with a new pump. Smear some grease on the o-ring and it'll be good.

Where you need to worry about rust is at the very bottom of the tank where water will accumulate, usually near the straps. If that area is rusty, you might have pinholes developing.

Tanks are cheap, but they're a real PITA to change.

As for the connector, they stuck it up there before they dropped the body on the frame. It's meant to be where it is and you ain't getting it out. There might even be a Christmas tree holding it in place.
_________________________

1988 CVLX (Love Boat) POTM July 2019 50K
E-code lights w/ relays, LEDs w/ switchbacks, Kenwood stereo, various hacks.
1988 CVLX (Destroyer) 1998-2001 driven to death 202K
1988 Squire (Chris Craft) 1996-1998 junkyard rescue driven to death 199K

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#4051680 - 03/11/20 07:52 PM Re: Fuel pump replacement issue on a 2002 GM [Re: lmrogp]
BigMerc96 Offline

I know nothing
Posting Addict

Registered: 06/05/10
Posts: 19394
Loc: I can see Detroit from here!
Actually, its not supposed to be trapped like that. Your body mounts are collapsed a bit, thus the body and frame are closer together than they ought to be. Ran into that on my Town Car. Easy solution though: Put a floor jack under the pinch weld on the rockers while the frame is still supported on the stands, and raise the body. Hopefully there is enough left of your rockers to do so. I'm amazed there was enough left on my Townie seeing as it pretty much has no rockers, but the inner pinch weld was still solid enough to raise the body. You aren't trying to lift the car, just take some of the body's weight off of the frame/mounts.
_________________________
-Steve

2006 Audi A6 ~132k miles, stock.
1998 Mercury Grand Marquis LS HPP ~100k miles, slowly acquiring modifications.
1997 Town Car Cartier ~145k miles, Ported Plenum, Gutted Airbox, Contour E-fan Retrofit, Dual exhaust with Magnaflows, cats deleted, MSD Ignition, KYB Gas-A-Justs, P71 front bar, air ride reinstated, Projector retrofit, Caddy 4-note horn retrofit, Wood rim steering wheel retrofit, holistic weight reduction as the parts fall off..
1996 Mercury Grand Marquis GS 117,485mi. R.I.P. 7/14/12 frown

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#4051688 - 03/11/20 08:50 PM Re: Fuel pump replacement issue on a 2002 GM [Re: lmrogp]
Bangster Offline

Poobah

Registered: 11/30/01
Posts: 8938
Loc: Tucson Az
I didn't disconnect any wiring or fuel/return lines, didn't drop the tank, and spent more time replacing exhaust hangers I found lacking when doing the pump on my Grand Marquis. I used a universal replacement that needed the connector cut and crimped, and it was still going strong at 330,000 miles.

Mine is not rusty, but I would think that would be more reason to not tempt fate with the straps or the tank, though those bolts look nasty but pretty accessible to penetrating oil a few times and I think they are pretty straight shot to get it.
_________________________
00 Grand Marquis LS Premium - 97 Cougar 4.6 Sport - 89 Cougar LS - 63 Falcon 302 - 82 F-150 - 97 Mark VIII LSC - 2017 Escape SE - 2012 Fusion Sport AWD

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#4051730 - 03/12/20 02:34 AM Re: Fuel pump replacement issue on a 2002 GM [Re: BigMerc96]
lmrogp Offline
Member

Registered: 01/02/09
Posts: 215
Loc: Sin City
Originally Posted By BigMerc96
Easy solution though: Put a floor jack under the pinch weld on the rockers while the frame is still supported on the stands, and raise the body. Hopefully there is enough left of your rockers to do so. I'm amazed there was enough left on my Townie seeing as it pretty much has no rockers, but the inner pinch weld was still solid enough to raise the body. You aren't trying to lift the car, just take some of the body's weight off of the frame/mounts.

Worked perfectly...thanks!



_________________________
2009 Ford Crown Victoria Police Interceptor
Silver Birch Metallic, SAP, 118k, 867h, 3.27, Dual Exhaust, Mustang Wheels, LTC Jump Seat, OEM RKE Retrofit, BH1976 Headlight Relay Harness, Engine Compartment Light

2002 Mercury Grand Marquis GS
Spruce Green Metallic, 201k, 3.73, ETE Reman Transmission, DRP Tune, Dual Exhaust, HPP Wheels, Bilstein Shocks, VDO Tach, Compass Mirror, Factory AM/FM/CD Player

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#4051754 - 03/12/20 09:06 AM Re: Fuel pump replacement issue on a 2002 GM [Re: lmrogp]
BigMerc96 Offline

I know nothing
Posting Addict

Registered: 06/05/10
Posts: 19394
Loc: I can see Detroit from here!
For the record, I didn't bother looping that connector over the frame. I put a couple zip-ties around it to hold it up to the frame below where the factory had it. Its not like its somewhere where the harness should ever get pulled on.
_________________________
-Steve

2006 Audi A6 ~132k miles, stock.
1998 Mercury Grand Marquis LS HPP ~100k miles, slowly acquiring modifications.
1997 Town Car Cartier ~145k miles, Ported Plenum, Gutted Airbox, Contour E-fan Retrofit, Dual exhaust with Magnaflows, cats deleted, MSD Ignition, KYB Gas-A-Justs, P71 front bar, air ride reinstated, Projector retrofit, Caddy 4-note horn retrofit, Wood rim steering wheel retrofit, holistic weight reduction as the parts fall off..
1996 Mercury Grand Marquis GS 117,485mi. R.I.P. 7/14/12 frown

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#4054674 - 03/26/20 01:42 AM Re: Fuel pump replacement issue on a 2002 GM [Re: lmrogp]
lmrogp Offline
Member

Registered: 01/02/09
Posts: 215
Loc: Sin City
I finished this job last week and am very happy with the result. Was able to remove the old 200k miles pump by rotating and finessing it between the tank and exhaust pipe. Even though the tank has some surface rust, the pump mounting surface was perfectly clean.



Opted for a new Ford pump, here it is sitting next to the old one.



As for the sensor connection on the top of the tank, I briefly attempted to disconnect it with the help of a curved pick tool, but gave up when it became clear I was more likely to break the connector. Instead, I went the splice and solder route for those three wires. Used the solder seal connectors for the first time. Combination heat shrink and low temp solder. I tested first and was impressed with the result.



Here are the splices, with an extra heat shrink layer over the solder seal, just for security.



The splices are very compact, so I was able to fit everything back into the wire loom that came with the new pump. Also re-positioned the other electrical connector and zip tied in place, and used some clean fuel line safety clips that I harvested from the boneyard.



Torqued the pump screws to spec, and have had absolutely no leak issues. The new pump is working great, its quiet and there is no more priming needed when starting the car.
_________________________
2009 Ford Crown Victoria Police Interceptor
Silver Birch Metallic, SAP, 118k, 867h, 3.27, Dual Exhaust, Mustang Wheels, LTC Jump Seat, OEM RKE Retrofit, BH1976 Headlight Relay Harness, Engine Compartment Light

2002 Mercury Grand Marquis GS
Spruce Green Metallic, 201k, 3.73, ETE Reman Transmission, DRP Tune, Dual Exhaust, HPP Wheels, Bilstein Shocks, VDO Tach, Compass Mirror, Factory AM/FM/CD Player

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#4054710 - 03/26/20 09:02 AM Re: Fuel pump replacement issue on a 2002 GM [Re: lmrogp]
Fordiesel69 Offline

Over the Hill

Registered: 09/16/05
Posts: 4371
Loc: Erie, PA
How many kidneys did you have to shell out for that sucker?
_________________________
rant2 ******Need your heater core replaced? Click Here******rant2
-'99 Crown Vic Police Interceptor (SAP), 3.55 Trac-Loc(DK), Cloth Interior, Black Honeycomb Grill, Black PI Trunk Bezel, Silverstars, 183K
-'00 Crown Vic Police Interceptor (SAP), 3.55 (R2), Cloth Interior, Black PI Trunk Bezel, 03+ Full Wheel Covers, Silverstars, 115K
-'08 Crown Vic Police Interceptor (SAP), 3.27, Cloth Interior, Smokestone Metallic, 96K / 249 Hrs
-'08 Crown Vic Police Interceptor (SAP), 3.27, Cloth Interior, Black, 133K / 1643 Hrs
-'08 Crown Vic Police Interceptor (SAP), 3.27, Cloth Interior w/ Carpet, Norsea Blue, 157K / 597 Hrs
-'07 F-150 4x4 - Extended Cab, 3.55's, White w/ Grey interior, 167K
-'14 Fusion S - 160K

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#4054752 - 03/26/20 03:35 PM Re: Fuel pump replacement issue on a 2002 GM [Re: lmrogp]
crjackson Offline
Member

Registered: 09/02/15
Posts: 103
Loc: Charlotte, NC
Glad you got it worked out. I had the same problem with trapped wiring when I did my fuel pump.

I used a prybar and it quickly made the space needed to R/R the wiring. Just adding another solution if someone else runs into this..


Edited by crjackson (03/26/20 03:36 PM)
_________________________


1998 Crown Victoria LX, 4.6L V8, 158,000 mi., All original equipment
2014 Mustang GT, 5.0 Premium 401A, Track-Pack, Comfort Pack, Tech Pack, 4K mi. Some Mods...
2018 Black Nissan 370Z Nismo Tech, All Options, 1K mi., All original equipment



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#4054762 - 03/26/20 05:28 PM Re: Fuel pump replacement issue on a 2002 GM [Re: lmrogp]
BigMerc96 Offline

I know nothing
Posting Addict

Registered: 06/05/10
Posts: 19394
Loc: I can see Detroit from here!
Last time I looked them up, the Motorcraft assemblies weren't all that expensive for a '98-'02. For my '97 tho, that's too much, it just got a Delphi pump motor on the original hanger. I bought the car with a new tank in it, I never thought anything about the pump. They obviously reused the original pump seeing as it was stamped 8/26/1996 when the car was built 9/5/96. Turns out it has a '96 tank in it, so there is no spot for that fuel tank pressure sensor ('95-'96 don't have one cuz they don't have an EVAP system monitor, '97 is a one year only tank), and I found it zip tied to the frame so I guess it saved me the work of cutting/splicing those wires. Funny that I never got a code for that, it being plugged in must be enough to satisfy the computer.
_________________________
-Steve

2006 Audi A6 ~132k miles, stock.
1998 Mercury Grand Marquis LS HPP ~100k miles, slowly acquiring modifications.
1997 Town Car Cartier ~145k miles, Ported Plenum, Gutted Airbox, Contour E-fan Retrofit, Dual exhaust with Magnaflows, cats deleted, MSD Ignition, KYB Gas-A-Justs, P71 front bar, air ride reinstated, Projector retrofit, Caddy 4-note horn retrofit, Wood rim steering wheel retrofit, holistic weight reduction as the parts fall off..
1996 Mercury Grand Marquis GS 117,485mi. R.I.P. 7/14/12 frown

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#4054770 - 03/26/20 06:07 PM Re: Fuel pump replacement issue on a 2002 GM [Re: lmrogp]
Bangster Offline

Poobah

Registered: 11/30/01
Posts: 8938
Loc: Tucson Az
Great job and pictures and details for someone else that might find the post!
_________________________
00 Grand Marquis LS Premium - 97 Cougar 4.6 Sport - 89 Cougar LS - 63 Falcon 302 - 82 F-150 - 97 Mark VIII LSC - 2017 Escape SE - 2012 Fusion Sport AWD

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#4054838 - Yesterday at 12:03 AM Re: Fuel pump replacement issue on a 2002 GM [Re: Fordiesel69]
lmrogp Offline
Member

Registered: 01/02/09
Posts: 215
Loc: Sin City
Originally Posted By Fordiesel69
How many kidneys did you have to shell out for that sucker?

Cost me $320 through Amazon. Dealer wanted almost $600.
_________________________
2009 Ford Crown Victoria Police Interceptor
Silver Birch Metallic, SAP, 118k, 867h, 3.27, Dual Exhaust, Mustang Wheels, LTC Jump Seat, OEM RKE Retrofit, BH1976 Headlight Relay Harness, Engine Compartment Light

2002 Mercury Grand Marquis GS
Spruce Green Metallic, 201k, 3.73, ETE Reman Transmission, DRP Tune, Dual Exhaust, HPP Wheels, Bilstein Shocks, VDO Tach, Compass Mirror, Factory AM/FM/CD Player

Top

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