Replacing the fuel pump for a Ford Mondeo 4

If fuel from the gas tank stops flowing to the engine, the car will not go far. This applies to all cars. Fort Mondeo is no exception. A disruption in the fuel supply to the engine can occur for various reasons. But the most common is a fuel pump failure. If this is exactly what happened, the owner of a Ford Mondeo car has no need to go to a car service center. You can replace the fuel pump yourself, and you don’t even have to remove the gas tank to do this. Let's figure out exactly how this is done.

Ford Mondeo 4 Removal, repair and installation of fuel module

If engine power drops, increased noise occurs, or whines are periodically heard when the fuel pump is operating, then most likely the fuel pump has failed. First check the pressure in the fuel supply system (see Checking the pressure in the engine supply system). If the pressure in the system is below 360 kPa (3.6 kgf/cm2), the fuel pump must be replaced or repaired. You will need: a hardwood drift, a hammer, a container for draining fuel. 1. Remove the fuel tank (see Replacing the Fuel Tank). NOTE. It is necessary to remove the fuel tank to replace the fuel pump because the Ford Mondeo does not have a hatch in the base of the body above the fuel module, so access to it with the tank installed on the car is impossible.

2. Pry up the clamp of the fuel module wiring harness...

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

4. Pry up the fuel line tip retainer...

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

6. Loosen the tightening of the pressure 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 neck of the fuel tank.

8. Carefully remove the fuel pump module, turning it so as not to damage or displace the fuel gauge sensor float, 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 up the fuel filter retainer...

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

12. Disconnect the ground wire terminals from the fuel pump guide terminals.

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

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

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

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

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

18. Pry up the fuel pump module cup clamps...

19….and remove the glass from the module.

20. Pry up the fasteners of the fine fuel filter...

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

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

23….and remove it from the module body. 24. Remove the fuel supply hose from the fuel pump.

25. Pry up the fuel pump clamps...

26….and remove it from the fuel module.

27. Pry up the clamps on the tip of the fuel drain hose...

28….and remove the hose connector from the fuel pressure regulator. 29. Assemble and install the fuel module in the reverse order of removal.

The fuel pump in the form of a step is not expensive

Be extremely careful not to damage wires and hoses. Before disconnecting the fuel pipes, it is recommended to reduce the pressure in the system.

It is enough to remove the chip from the fuel pump and start the car. The engine will use all the fuel in the system and will stall itself. Smoking is strictly prohibited during work! Instructions on how to remove the fuel pump To achieve the desired result, follow the following algorithm: To make the hole more or less even, it is best to first draw its outline on the metal surface with a felt-tip pen.

After making the hole, you can remove the pump itself. Before doing this, it is recommended to cover the sharp edges of the hole with masking tape to avoid injuring your hands.

How to change the fuel pump on a Ford Mondeo yourself

Choosing a fuel pump: analogues or originals?

Choosing a fuel pump is a purely individual matter. Here everything largely depends on the financial capabilities of the car owner and his attitude towards Chinese or European parts. It is safe to say that the Ford Mondeo will work perfectly with both the Chinese and the original pump. What distinguishes them is not so much the quality as the price tag.

Advice! Unfortunately, you won’t be able to just point at the pump you like in an online store. You will have to select the part by volume. This can be done very simply: specify the year of manufacture and model of the car in the filters. For example, this is a Ford Mondeo 3 produced in 2012.

Popular models, not counting the original fuel modules from Ford, are: PROFIT, BOSCH, ATS, ACHR, VDO, etc.

About fuel pumps installed on Ford Mondeo of different generations

As you know, Ford Mondeo cars have been subjected to so-called restyling more than once. To date, there have been four generations of these machines. Restyling of the first three generations of cars mainly affected their bodies and interiors.

Noise and heat insulation was improved, and the shape of the radiator grilles and instrument panels was slightly changed. There were no significant changes to the engine and chassis. These changes appeared only in the fourth generation Ford Mondeo. But not a single restyling affected the fuel pumps themselves. So the fourth generation pump is no different from the first generation pump.

Fuel pumps for Ford Mondeo can differ only in their operating principle. They can be:

Dismantling on Ford Mondeo cars 1st, 2nd, 3rd and 4th generations

Before proceeding to describe the process of dismantling the pump, one important clarification should be made. As mentioned above, the fuel pump is located under the interior floor, but it is impossible to remove it through the standard hole. The official instructions state that to replace the fuel pump, the car owner will have to completely remove the gas tank. This is a very difficult and lengthy procedure that not everyone can do. Therefore, domestic car enthusiasts have found a way to remove the fuel pump without removing the gas tank. This method is not aesthetically pleasing, but it is effective and takes minimal time. For this reason, it will be considered below. But first, let's decide on the tools that will be needed for the job.

Tools and Supplies

rags;
metal scissors;
flat blade screwdriver;
set of open-end wrenches.

Sequence of actions when removing a gasoline pump

The rear door opens, the rear seat is removed, and the carpet is removed from the floor. This opens access to a metal plug, under which there are fuel lines and a pump.

Important points

Before removing the fuel pump, it is very advisable to drain all gasoline from the gas tank. Not everyone does this and not always, but completely draining the fuel will make all further work much safer;
Only use scissors to cut a hole in the floor. Under no circumstances should you use a chisel or grinder. Any spark from these tools may cause fire and explosion;
when cutting through the floor covering, you should be careful, as you can easily damage or completely cut the fuel line hoses;
all work must be carried out in a well-ventilated area, and ideally in the open air;
There should be no open sources of fire near the car. While performing work, you should refrain from smoking and be sure to keep a fire extinguisher at hand;
If you need to illuminate something in the cabin, you should use only an electric flashlight. The use of matches or lighters is strictly prohibited;
all work should be carried out wearing glasses and protective rubber gloves;
Before disconnecting the fuel line hoses, you should place several pieces of rags on the fuel pump cover. Despite the release of pressure in the system, gasoline still remains in the fuel hoses. And it can flood the floor of the cabin.

So, in order to remove the fuel pump, you do not need to blindly follow the instructions. Sometimes you can use your wits and thereby save yourself from the serious headache that will inevitably arise if a car enthusiast tries to remove the gas tank from a Ford Mondeo alone. And of course, when dealing with gasoline, we should never forget about safety precautions and personal protective equipment.

The fuel pump stopped working at 55 thousand mileage

Good afternoon, forum members. So I decided to tell a story about my 2012 Russian-assembled Mondeo, 2.3 engine, mileage 55 thousand km. Before that, I drove exclusively Japanese-made cars and didn’t know what warranty repairs were! Three weeks ago I left the house, got into my favorite car - I really like it, really - turned the ignition key and realized with horror that the car wouldn’t start - the starter was turning, but the engine wouldn’t crank. I pulled out the key, inserted it, turned it to position 2, waited until the electronics turned on, and tried to start again - the starter turned, but the engine did not catch. And this despite the fact that I did TO 60 a couple of hundred kilometers ago. Wow. I called my friend. He said - you apparently started up abruptly, didn’t wait 10 seconds and immediately turned the key. It is recommended to give the electronics time to perform self-diagnosis before starting it. If you don't do this, the machine may become dull. In such cases, you need to restart the car's brains - I did this in the most primitive way - I removed the stigma from the battery for a couple of minutes and, full of hopes for success, tried to start again. The picture is the same - the starter turns, but the engine does not catch. And then I noticed the absence of such a familiar sound to the ear - the pump turning on. For the first few seconds it can be heard on the right from under the panel. And I realized that the pump was dead, and I was also very glad that I extended the warranty, because the three-year warranty had expired. Then I decided it was time to call Ford roadside assistance. They answered immediately. They asked for the car's VIN code. I dictated. The girl entered something for several minutes, then asked if I said the VIN code correctly and in the end we found out that no data about me was found in the system, and that the only maintenance I did, according to Ford, was the first one at 13 thousand kilometers. one year after purchase. Wow. I had to open the service book and dictate where I last carried out maintenance. The girl took a time out and said she would call back. My wait lasted half an hour. While I was waiting, I diagnosed the car myself. Two errors popped up - but after searching the Internet I discovered that one of them pops up even in new cars, and the second is a consequence of the first - that is, the diagnostics didn’t really let me understand anything, of course I need to connect the computer and look specifically. Then they called me back, apologized for the misunderstanding, said that they had brought me back to the database and asked what happened to me. I explained the problem. I was connected to a technician. She asked me to determine if there was any sound from the pump - I said no and they immediately offered me a tow truck. Another hour was spent searching for a dealer to take the patient to. Ford connected me with dealers, and they, in turn, learned about my problem and offered me an appointment in a week, two, three. But I was lucky - where I did the last maintenance, they first offered an appointment in a week, and then they called back and said that they could accept me today. I'm back at Ford - I ordered an evacuation. Strangely enough, the tow truck arrived in 30-40 minutes; honestly, I was very surprised by such diligence. We loaded the car, drove to the dealer, and filled out the paperwork. They told me: diagnostics cost 2 thousand rubles. Of course I agreed. I waited the whole day for a call (I handed over the car at about 11 am), and already despairing that they would call me, I wanted to dial it myself, when at about 6 pm the master called me and said: Diagnostics showed a malfunction in the pump, you need to look at it in detail, and for this you need remove the gas tank. Are we filming? - Yes, what is the question, of course, remove it if necessary. But it turns out that removing the tank costs money and quite a lot - 6 thousand rubles and kopecks. In total, the entire diagnostics already exceeded 8 thousand. I agreed - after all, I had no choice. And then I thought - I filled in bad gasoline, the filter is clogged, they will clean it, and so on. A friend had this on a Kruzak - they also removed the tank. All the fun cost 50 thousand. On my previous car, an Outlander Xcel, there were already problems with gasoline, the catalyst check popped up, and gas control helped. In general, they said we’ll call back later. They called back around nine in the evening - they work there around the clock. And they said: “You have some kind of nonsense there.” I’m honestly not good at mechanics, but from the words of the foreman I understood that the pump had defective connectors for connecting power, and to put it simply, the wires fell out of it, so he didn’t even think turn on. and then the master added that since the part was defective, they would do everything under warranty. You can imagine how happy I was. Now I’ve been waiting 3 weeks for it to be done for me. Work there for a couple of hours. But they are waiting for details. Based on the results, if anyone is interested, I’ll post. Before this, by the way, I also complained about a strange sound from the steering column - it turned out that my electrical wire was not inserted all the way, that’s why it was making noise. Now I’m thinking about the periodic jerking of the box, and in general, that there may still be defects.

Replacing the fuel pump on a Ford Mondeo with your own hands without removing the tank

16.10.2014 5 258

Replacing the fuel pump on a Ford Mondeo is an unpleasant procedure, which also requires the removal of the fuel tank, at least that’s what the owner’s manual says. However, “our man” would not be “our man” if he had not found a way out of this unpleasant situation.

As you understand, in this article I will tell you about a method that allows you to replace the Mondeo fuel pump without removing the gas tank , if you are interested, then read on. I will not write about how to check the fuel pump or how to understand that it needs to be changed; we will talk directly about how to remove and replace the fuel pump.

The fuel pump is located in the tank, which in turn is located under the rear seats, which means it can be reached through the cabin. To get to the fuel pump from the passenger compartment, you need to lift the rear seat from the filler neck. Removing the seat, you will see a black plug with a protruding wire that goes directly to the fuel pump.

How to replace the Ford Mondeo fuel pump without removing the fuel tank?

Everything ingenious is simple! So it is here. Once you open access to the fuel pump, you will encounter a problem: it will not fit into the hole in the floor in the cabin. The way out of this situation is not the most pleasant and humane, but it is simple and quick; in order to get the fuel pump you will have to enlarge the hole in the gas tank. For this you can use, for example, metal scissors.

Disassembling the fuel pump and replacing its main module

Before disassembling the fuel pump, removed from the standard niche, it is necessary to disconnect the fuel sensor from it. This is done using pliers (extreme care should be taken when performing this operation: the sensor is very fragile).

Ford Mondeo fuel pump fuel sensor is disconnected with pliers
After disconnecting the sensor, open the cover of the fuel pump housing. This cover is held in place by six plastic latches. You can disengage them using a flat-head screwdriver.

The latches on the outer housing of the Ford Mondeo fuel pump are disconnected with a flat screwdriver
Under the cover there is a fuel pump module. It is removed manually.

The main module of the Ford Mondeo fuel pump is located under the housing cover
A new module is installed in its place, after which the unit is reassembled.

Ford Mondeo fuel pump module, which will be installed instead of the old one

Important notes and tips:

Before you start cutting, try to drain all the fuel from the tank.
Do not use a grinder for cutting; sparks can cause a flash and the consequences will be disastrous.
During the cutting process, be careful not to cut the fuel hoses.
Before disconnecting the fuel lines, it is necessary to relieve the pressure in the system. To do this, take out the chip responsible for the fuel pump and start the engine. Let it run until it stalls.
Do not smoke or place fire near an open opening in the tank. If you need to illuminate, use a flashlight.

Where is the fuel pump: navigation for beginners

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Many drivers find it difficult to find this element of the fuel unit. It is logical that its location is in close proximity to the main unit - the fuel tank. More precisely, the pump is located directly in it. Next to it is another element of the system - the fuel level sensor.

Important! If you are forced to dismantle the pump, you have to perform two operations: drain the fuel and reduce the pressure in the system. This advice is universal for any work on the fuel system.

Remember that any work on the fuel system is carried out with an empty tank and normalized pressure.

From words to action.

1. Take metal scissors and start cutting. If you have not worked with such a tool before, I recommend practicing before you start “cutting your car.” To make the hole more or less decent, use a marker, use it to draw a circle of the required size, and only then start cutting.

2. Once the hole is made, you can remove the fuel pump. To avoid cutting yourself on the sharp edges of the enlarged hole when installing a new fuel pump, wrap them with tape or use a rubber tube. After cutting it in half lengthwise, put it on the end of the hole, as in the photo.

3. Do not rush to throw away the fuel pump; perhaps it is in good working order and you just need to replace the mesh or some parts of the pump itself.

4. After replacing the fuel pump strainer, repairing the fuel pump or completely replacing it, install the new fuel pump in place. Reconnect all fuel hoses and reassemble everything in reverse order.

PS One unpleasant question arises: “What to do with the hole?” Everyone will have their own answer to this question, some will come up with a lid, others will not bother and seal everything with tape. In fact, this does not play a big role, the most important thing is that nothing foreign gets inside the tank. Personally, I would advise making a metal lid, putting a rubber cuff around the edges and placing the whole thing on sealant and screws. It will be secure and airtight.

That's all for me, thank you for your attention, I hope you will be able to replace the Mondeo fuel pump without removing the tank . If you are not sure or you somehow don’t like this option, remove the tank or seek help from a professional.

Getting ready for repairs: what tools will you need?

Before you start repairing a Ford Mondeo, you should take care of what tools you will need for the job. We recommend checking your home tool kit for the following items:

Wrench for removing fuel hoses.
Key for removing the fuel pump.
Fuel filter lifting pliers
Fuel cap puller.
Key for fuel box cover.
Set of fuel caps.
Puller for fuel intake.

Check if you have everything in stock. This will allow you not to waste time and complete all work efficiently. If one or more elements are missing, we recommend purchasing them in advance. There are no unnecessary tools in the house.