Ford introduced the Contour in 1995 and continued production until the 2000 model year. The 1999 Ford Contour was equipped with four different engine options: a 2.0-liter flex-fuel four-cylinder; a 2.0-liter in-line standard four-cylinder; a 2.5-liter V-6; and a 2.5-liter high output V-6. The fuel tank on the 1999 Contour is in the rear of the car, just in front of the back axle beam. Replacement of the fuel tank requires removal of interior parts of the vehicle as well as exterior. Replacing the fuel tank in the 1999 Contour can take three or more hours to complete if you have never done this type of work before.
Open the driver's side and passenger-side rear doors. Remove the back seat cushion from the rear of the Contour. Pull upward on the two pull tabs on the front of the seat cushion to release the seat locking tabs. Turn the seat vertical so the front of the seat if facing upward. Remove the rear seat cushion from the car.
Open the fuel door, and remove the gas cap to relieve the pressure from the fuel tank. Replace the gas cap after approximately 20 seconds.
Remove the plastic grommet from the floorboard of the car, using a flat-head screwdriver to pry the grommet free. Removing this panel exposes the top of the fuel pump, which is mounted into the top of the fuel tank. Remove the three small fuel hoses attached to the top of the fuel pump by pinching the plastic retainer tabs and pulling the lines free from the fuel pump. Remove the electrical connector from the fuel pump in the same manner, pinching the retaining tab and pulling the connector free of the fuel pump.
Raise the rear of Contour using a 2-ton jack or a jack with greater capacity. Place jack stands beneath the rear axle beam on each end of the beam just behind the rear wheels. Lie beneath the rear bumper of the Contour, and position your body so you can physically access the fuel tank.
Remove the fuel filler and vapor hoses from the side of the fuel tank by loosening the hose clamps, using a 3/8-inch ratchet and socket with a 4-inch extension. The addition of the extension will give you the reach you need to place the socket on the hose clamp while still having maneuverability with the ratchet. Pull the hoses off the tank by hand once you have sufficiently loosened the hose clamps.
Remove the fuel filter bracket from the front of the fuel tank. Use a 3/8-inch drive ratchet and socket to remove the bracket bolts, then remove the bracket by hand. You can allow the filter and bracket to hang freely.
Set the jack beneath the fuel tank, and place a length of wood -- 1 foot long by 4 inches wide by at least 1/2-inch thick -- onto the head of the jack. The board will act as a leveling shelf for supporting the fuel tank while also ensuring you do not puncture the fuel tank with the small head of the jack. Lift the jack with the board up to the bottom of the fuel tank, and rest the board against the tank. Do not lift up on the fuel tank, but set the board against the tank to brace the weight of the tank.
Spray penetrating spray onto the fuel tank strap mounting bolts. Allow the penetrant to sit for no less than five minutes.
Remove the fuel tank strap mounting bolts with a 3/8-inch drive ratchet and socket after allowing the penetrating spray to perform its function. Turn the bolts counterclockwise until they are completely free from the bottom of the Contour. Pull the fuel tank straps downward by hand and off to the sides of the fuel tank.
Lower the fuel tank by lowering the jack. Set the fuel tank on a large piece of cardboard. Using one side of the new fuel tank box will work for this procedure. Placing cardboard between the tank and ground will ease the process of moving the fuel tank while eliminating the chance of static charges building between the fuel tank and the ground. Remove the old fuel tank from beneath the Contour, making sure the tank stays on the large piece of cardboard.
Remove the retaining nuts from the heat shields attached to the old tank using a 3/8-inch drive ratchet and socket. Transfer the shields to the new tank, and tighten the nuts onto the new tank. Remove the fuel pump locking cam by tapping a screwdriver against one of the upward protruding tabs using a hammer. Gently tap the tab so the locking cam or lock ring turns counterclockwise until the ring pops upward and free from the fuel tank. Make a mental note of the physical position of the fuel pump tubes and connector socket. You will place the pump in the new tank exactly in the same position.
Set the new fuel tank directly next to the old tank so both tanks are facing the exact same way. Remove the fuel pump from the old tank by hand, and set the pump into the new tank in the exact same position as it was removed from the old tank. Turning or repositioning the fuel pump in the new tank will cause complications during the installation of the fuel pump. Insert a new fuel tank locking cam on top of the fuel pump. Push the cam downward, and turn it clockwise physically until the locking tabs begin to align on the new tank.
Remove the cardboard from beneath the old fuel tank. Set the new fuel tank onto the large piece of cardboard. This will ensure you do not damage the bottom of the new tank while transferring the new tank to the Contour. Set the new fuel tank beneath the Contour, and set it in position for installation.
Place the length of wood back atop the head of the jack. Place the new fuel tank on top of the wooden board. Raise the new fuel tank using the jack, until the tank rests against the bottom of the Contour. Do not push upward on the tank once it hits the bottom of the car or you can crush the seals around the sides of the new tank. Install the fuel tank straps around the new fuel tank, and tighten the fuel tank strap mounting bolts between 29 and 21 foot-pounds of torque, using a certified torque wrench and socket.
Install the fuel filler hose and fuel vapor hose onto the new fuel tank by hand. Tighten the hose clamps on the hoses until they are snug, using a 3/8-inch drive ratchet and socket. Once the clamps are snug, turn the clamp 1/4-turn tighter. This "snug-and-a-quarter" method of tightening the clamps is sufficient and will not damage the tubing or the clamps during installation. Install the fuel filter and fuel filter bracket onto the front of the new tank, and tighten the mounting bolts using the "snug-and-a-quarter" turning method.
Enter the rear of the Contour. Install the small fuel hose onto the fuel pump by pushing them on by hand. Reinstall the fuel pump electrical connector in the same manner. Insert the plastic grommet back into the floorboard hole, and tap the grommet down gently with a hammer.
Install the rear seat cushion into the back of the car, turning the seat vertical so the front of the seat is facing upward. Set the back of the seat cushion down, and pull the seat belts and seat belt fasteners up and over the back of the seat. Push the back of the seat toward the rear of the car and downward, then push the front of the seat cushion straight down. Tug upward on the front lip of the seat cushion to ensure the seat is locked in place. Reposition the seat, and lock the seat down if necessary.
Open the fuel filler door. Remove the gas cap, and pour at least 3 gallons of fuel into the new tank. Replace the gas cap. Turn the ignition key on the Contour to the "II" or accessories position, and then back to the "Off" position. Repeat this key turning process no less than three times, as this will prime the entire fuel system with fuel and pressurize the system to the correct operating pressure.
