Hello All,
It’s been a long time since I’ve been on the forum and almost as long since I’ve worked on my Cougar. Hopefully, now that I’m re-engaged with my car, I’ll be on more 
I tried starting it a few weeks ago and noticed a fuel leak coming from the fuel pump. So I did some research and found a rebuild kit sold at CJ Pony Parts. Long story short, I’m unsure how the lever attaches to the diaphragm. Below is photo of the the replacement part with the lever inserted (obviously just for display). But this doesn’t seem right to me. One, the lever is pushing on the seal. Two, the seal won’t keep oil from the diaphragm. I tried to insert the lever between the top washer and seal, but couldn’t get them to separate. I found a couple of YouTube videos, but they either had a different diaphragm or glossed over this part. Any help is appreciated. Please let me know if I’ve not been clear or you have other questions.
Best regards,
Nick
Thanks Neal!
I had run across the second article when I was looking for the kit. Below is the step I’'m at.
Step 12: Reassemble the top half of the pump by pressing the large diaphragm into the top half of the housing. Place a little bit of white lithium grease on the internal end of the actuator arm. Fit the arm back into the housing so that it’s under the rubber washer and above the larger of the two metal washers on the plunger attached to the diaphragm. Be sure to line up the holes in the arm with the holes in the housing. Grease the new pin and install it in the housing to hold the arm in place.
Based on this description, I’ve got it right, but how does the rubber seal keep the oil from the diaphragm?
Best regards,
Nick
Hello Nick. The pre-assembly photo that you show is correct. The oil seal for the pump’s base casting is the rubber seal that’s wrapped around the top (smaller) spring retainer plate of the diaphragm assembly. The rubber oil seal will seat, via diaphragm spring pressure, against the inner recessed area of the base casting during reassembly of the base & valve chamber castings. I would recommend coating the rubber oil seal with a thin coat of lithium grease at reassembly. The smaller phenolic washer that rests between the top of the diaphragm assembly and rocker arm lever has dual purpose. 1) As a friction / wear pad during pump operation. 2) As a guide that keeps the diaphragm stem (plunger) vertical during the upward stroke of the rocker arm lever.
At reassembly, the rocker arm lever and phenolic guide washer should also be well lubricated with high temp lithium grease. Greasing the rocker arm / diaphragm stem cavity area of the base casting prior to diaphragm insertion allows easier access. More lubrication is better than too little in this area.
Another tip for easier pump reassembly is to complete the base casting portion of the process prior to reattaching the valve chamber casting.
Doing so will aid in re-installation of the rocker arm lever & rocker arm lever spring. The diaphragm being exposed during this part of the assembly process will allow you to push the diaphragm stem further up into the base casting, which will then create clearance, for inserting the rocker arm lever in place below the phenolic guide washer. After this process has been successfully achieved, then rotate the diaphragm & plate assembly (using the lower plate) to align the cloth with the base casting’s (6) flange holes. If desired… one or two of the assembly screws can be used to keep the diaphragm cloth orientation correct while reassembling the base casting & rocker arm lever portion of the pump.
Hope the info helps. From '84 to '90… I formerly worked at a fuel pump & water pump manufacturing plant. And, had the privilege of visiting the Carter Fuel Pump manufacturing facility in Logansport, IN on several occasions. Best of luck with your Cougar Eliminator. 
Hi Gary,
Thanks for the detailed response. It will be helpful when I get back to the pump. It’s great to get others input before blindly proceeding and possibly ruining a perfectly good part.
I’m a bit jealous of your Carter visit. I’m sure it was really cool. I was fortunate to have visited a Honda plant in Bowling Green Kentucky as well as a Chrysler truck plant (I can’t remember the location).
Again, thanks for the input!
Best regards,