Fuel tank leak after replacing

Tiny
YAN SAILLARD
  • MEMBER
  • 2002 MERCURY COUGAR
  • 2.5L
  • V6
  • FWD
  • AUTOMATIC
  • 133,100 MILES
I recently replaced my fuel pump in my car.
I smelled gas and pulled a P0442 code. After filling it up, I found the tank leaked at the fuel pump mount. I put a new Motorcraft seal in, but it did not fix the leak. I took it out and ensured all surfaces and o-ring were clean. I ensured the pump plate laid flat before tightening down the lock ring. It still leaked. I have a new Motorcraft locking ring coming tomorrow, hoping that will solve the leak. Am I missing anything? Is there a sealant to use? I have done this several times before, but not on anything this new and have never had this issue.

Another question regarding the fuel line. I cannot find any definitive information on how to remove this line from the pump. I am assuming pinch the tabs and pull. Is this correct?
Friday, June 17th, 2016 AT 8:13 PM

4 Replies

Tiny
YAN SAILLARD
  • MEMBER
  • 8 POSTS
The line.
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Friday, June 17th, 2016 AT 8:18 PM
Tiny
JOHNNY G.JR
  • MECHANIC
  • 320 POSTS
Auto supply sells tool to remove those fittings
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Saturday, June 18th, 2016 AT 8:54 PM
Tiny
YAN SAILLARD
  • MEMBER
  • 8 POSTS
Thanks for the suggestion Johnny, but I finished it yesterday. I hope to never have to see this vehicles pump again so I'll just make a mental note of the tool.

After a new seal and locking ring, I did a closer inspection of the tank mounting surface. Lots and lots of rust, built up gunk, etc. I cleaned off the rust with a screw driver and brush. It was surprising to see how many flakes came off.

What I figure is that there was enough rust to cause the fuel pump and locking ring to sit barely above the seal and not make 100% contact.

P0442 code no longer shows up.
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Sunday, June 19th, 2016 AT 10:12 AM
Tiny
KEN L
  • MASTER CERTIFIED MECHANIC
  • 48,289 POSTS
Good to hear you got is fixed up, thanks for your input JOHNNY G.JR

Here is a video that will help for future reference.

https://youtu.be/SOmd3BoE4YU

Best, Ken
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Monday, June 20th, 2016 AT 9:10 AM

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