[Grayhawk1976]

Got a good one this week. 2001 cougar 2.5 return less fuel system. Fuel pump cycles with fuel coming out of the module,the fuel filter, but not to the fuel rail. I replaced the fuel rail pressure sensor thinking this was the problem. I un hooked the fuel line from the sensor and no fuel comes out. Before I try blowing air through the lines, do any of you know what this thing actually is? To me it looks like another fuel pressure regulator of some sort, but I get no information about it from my ford service manual or the internet.

 

[B3NN3TT]

I think it’s called a “pulse modulator” of something like that. Some kind of damper.

 

[mmc757]

Yeah, its just a little diaphragm to absorb hydraulic fluctuations.

I'm skeptical about your indications. Are you sure the pump is providing pressure? I know you said you have fuel at the filter but are you sure its not just head pressure from being below the tank? Also, are you sure the fittings on the filter are all the way engaged?
If you have actual fuel pump discharge pressure at the outlet of the filter, there's no reasonable explanation for not having it at the fuel rail...its just a tube. Unless your tube has become damaged somehow but that seems unlikely.

The #1 fuel system problem on these cars is pump failure...by a long shot. Anything else is almost unheard of. It could be that the suction filter on the pump is clogged enough that its providing a bit of pressure but not enough flow.

 

[Grayhawk1976]

I'm leaning towards a damaged fuel line. When I cycle the fuel pump with the line unhooked at the pump or the outlet side of the filter, it will fill a 16 oz bottle 1/4 of the way. This is my son's car and of course he didn't hit anything 🙄

 

[Grayhawk1976]

Oh yeah I replaced the fuel pump 5 months ago and the car hasn't been drove on the road..

 

[Grayhawk1976]

Well I have to eat crow on this one. When I replaced the fuel pump in my son's car, the hoses on the unit was brittle and broken. I "temporarily" replaced the lines with clear braided hose so we could move the car around. Unfortunately the check valve and the outlet side of the fuel module are different sizes. Pulled the top off the fuel pump module, and the hose was off.

 

[B3NN3TT]

Sweet, thanks for the update. I love it when the answer is clear.