All about Ford Mondeo

Fuel pump/fuel gauge sender unit - removal and refitting
Fuel and exhaust systems / Fuel pump/fuel gauge sender unit - removal and refitting


Warning: Petrol is extremely flammable, so take extra precautions when you work on any part of the fuel system. Dont smoke, or allow open flames or bare light bulbs, near the work area. Dont work in a garage where a natural gas-type appliance (such as a water heater or clothes dryer) with a pilot light is present. If you spill any fuel on your skin, rinse it off immediately with soap and water. When you perform any kind of work on the fuel system, wear safety glasses, and have a Class B type fire extinguisher on hand.

Note: Ford specify the use of their service tool 23-038 (a large box spanner with projecting teeth to engage the fuel pump/sender unit retaining rings slots) for this task. While alternatives are possible, as shown below, in view of the difficulty experienced in removing and refitting the pump/sender unit, owners are strongly advised to obtain this tool before starting work. The help of an assistant will be required.

1 Relieve the residual pressure in the fuel system (see Section 2), and equalise tank pressure by removing the fuel filler cap.

Warning: This procedure will merely relieve the increased pressure necessary for the engine to run - remember that fuel will still be present in the system components, and take precautions accordingly before disconnecting any of them.

2 Disconnect the battery negative (earth) lead - see Chapter 5, Section 1.

3 Unbolt or fold forwards (as appropriate) the rear seat base cushion (see Chapter 11).

Withdraw from the vehicles floor the grommet covering the fuel pump/sender unit. Wash off any dirt from the tanks top surface, and dry it; use a vacuum cleaner to clean the immediate surroundings of the vehicles interior, to reduce the risk of introducing water, dirt and dust into the tank while it is open.

4 Unplug the fuel pump/sender units electrical connector (see illustration).

9.4 Unplugging the fuel pump/fuel gauge sender unit electrical connector
9.4 Unplugging the fuel pump/fuel gauge sender unit electrical connector (arrowed)

5 To disconnect the fuel feed and return pipes from the unit, release each pipes coupling, by squeezing together the protruding locking lugs on each union and carefully pulling the coupling apart. Use rag to soak up any spilt fuel. Where the couplings are difficult to separate, use a pair of pliers and a block of wood as shown, to lever the pipe out of the union. Considerable force may be required, but be as careful as possible to avoid damaging any of the components (see illustration).

9.5 If fuel couplings are difficult to release, use pliers and a block of
9.5 If fuel couplings are difficult to release, use pliers and a block of wood as shown to prise pipe end out of union - be careful not to damage pipes or unions

6 Release the fuel pump/sender units retaining ring by turning it anti-clockwise. As noted above, Ford recommend the use of service tool 23-038. For those without access to such equipment, a hammer and drift, or a pair of slip-jointed pliers, will serve as an adequate substitute - at least for removal (see illustration).

9.6 Fuel pump/fuel gauge sender units retaining ring can be released using
9.6 Fuel pump/fuel gauge sender units retaining ring can be released using ordinary tools as shown. Correct service tool will probably be required on refitting

7 Withdraw the fuel pump/fuel gauge sender unit, taking care not to bend the float arm. The float arm is mounted on a spring-loaded extension, to hold it closely against the bottom of the tank. Note the sealing ring; this must be renewed whenever it is disturbed (see illustrations).

9.7A Removing fuel pump/fuel gauge sender unit - take care not to bend float
9.7A Removing fuel pump/fuel gauge sender unit - take care not to bend float arm, and note how it is fitted on springloaded extension

9.7B Fuel pump/fuel gauge sender units sealing ring must be renewed
9.7B Fuel pump/fuel gauge sender units sealing ring must be renewed whenever it is disturbed

8 On refitting, use a new sealing ring, and ensure that the gauze filter over the base of the pump pick-up is clean.

9 Align the pump/sender unit with the tank opening, and refit it, ensuring that the float arm is not bent. Insert the unit so that the float arm slides correctly up the extension, until the units top mounting plate can be aligned with the tank opening and pressed onto the sealing ring. This may require a considerable amount of pressure; if so, be careful to avoid damaging any of the components. The Ford service tool provides the best way of holding the ring square to the tank and turning it at the same time.

10 Maintain the pressure while an assistant refits and engages the retaining ring. When the ring is engaged in the tank lugs, turn it clockwise to tighten it until it is secured.

11 The remainder of the refitting procedure is the reverse of removal. Observe the colourcoding to ensure that the fuel pipes are reconnected to the correct unions.


2018 www.fordmon.ru. All Rights Reserved.