Removal, repair and installation of the fuel module

If the engine power drops, there is increased noise, or howls are periodically heard when the fuel pump is running, then most likely the fuel pump is out of order.

Pre-check the pressure in the fuel supply system (see Engine Fuel Pressure Check). If the system pressure is below 360 kPa (3.6 kgf/cm²), the fuel pump needs to be replaced or repaired.

You will need: a hardwood drift, a hammer, a container for draining fuel.

1. Remove the fuel tank (see Fuel Tank Replacement).

NOTE: Removing the fuel tank to replace the fuel pump is necessary because the Ford Mondeo does not have a hatch in the base of the body above the fuel module, so it cannot be accessed with the tank installed on the vehicle.

2. Pry off the fuel module wiring harness block retainer..



3.... and disconnect the block from the terminals of the module.




4. Pry off the fuel line tip retainer…



5….and remove the tip from the fuel pump module housing.



6. Loosen the clamping ring securing the fuel pump module to the fuel tank by turning the ring counterclockwise with gentle hammer blows through a wooden drift..



7.... and unscrew the ring from the fuel tank neck.




8. Carefully remove the fuel pump module, turning it so as not to damage or displace the float of the fuel gauge sensor, and drain the fuel from it into a previously prepared container.



9. If the fuel module O-ring remains in the fuel tank opening, remove the O-ring and inspect it. Be sure to replace the ring if it is torn or severely compressed.



10. Pry off the fuel filter retainer..




11….and remove the filter from the module housing.



12. Disconnect plugs of a "mass" wire from conclusions of directing the fuel pump.



13. Pry off the fuel module wiring harness block..



14….and disconnect it from the terminals of the module case.




15. Pry up the clamps of the wire terminals of the fuel level sensor and remove them from the block.



16. Remove the wires of the fuel level sensor from the retainer on the module housing..



17….and remove the fuel level sensor from the module housing.



18. Pry the retainers of the fuel pump module glass..



19….and remove the glass from the module.



20. Pry the retainers of the fuel fine filter..



21….and remove the filter from the fuel module.



22. Pry off the holder of the electric fuel pump..



23….and remove it from the module case.

24. Remove the fuel supply hose from the fuel pump.



25. Pry off the fuel pump retainers…



26….and remove it from the fuel module.



27. Pry off the retainers of the fuel drain hose tip..



28….and remove the hose end from the fuel pressure regulator.

29. Assemble and install the fuel module in the reverse order of removal.