All about Ford Mondeo
Fuel tank - removal and refittingFuel and exhaust systems / Fuel tank - removal and refitting
Warning: The fuel system pressure must be released before any part of the system is disturbed - see Section 2. Petrol is extremely flammable, so take extra precautions when you work on any part of the fuel system.
Don’t smoke, or allow open flames or bare light bulbs, near the work area. Don’t 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.
1 A fuel tank drain plug is not provided; it is therefore preferable to carry out the removal operation when the tank is nearly empty.
Before proceeding, disconnect the battery negative (earth) lead, and syphon or handpump the remaining fuel from the tank.
Alternatively, disconnect the feed pipe from the fuel filter (see Chapter 1), and connect a spare length of hose to this so that when the ignition is switched on, the fuel pump will empty the tank into a clean container. If this approach is adopted, ensure that the container is large enough to take all the fuel in the tank, and be careful to take all suitable precautions to prevent the risk of fire. Note: Before disconnecting or opening any part of the fuel system, relieve the residual pressure (see Section 2), and equalise tank pressure by removing the fuel filler cap. Also disconnect the battery negative (earth) lead - see Chapter 5, Section 1.
2 Unbolt or fold forwards (as appropriate) the rear seat base cushion (see Chapter 11).
Withdraw from the vehicle’s floor the grommet covering the fuel pump/sender unit. Unplug the fuel pump/sender unit’s electrical connector, and disconnect the fuel return pipe (coded red) from the unit (see Section 9).
3 Raise the rear of the vehicle, and support it securely on axle stands. Get underneath and familiarise yourself with the layout of the fuel tank assembly before proceeding (see illustration).
10.4 Fuel tank assembly
Warning: Do not place any part of your body under a vehicle when it’s supported only by a jack!
4 Either remove the fuel filter, or disconnect its outlet pipe (see Chapter 1).
5 Unhook the exhaust system rubber mountings. Lower the system onto a suitable support, so that the front downpipe-toexhaust manifold joint is not strained, or remove it completely (see Section 17).
6 Unbolt the rear suspension anti-roll bar mounting clamps (see illustration). Swing the bar down as far as possible - if clearance is very restricted, it is advisable to remove the bar completely (see Chapter 10).
10.6 Unbolt rear anti-roll bar mounting clamps (one arrowed) when preparing to remove the fuel tank
7 Disconnect the flexible vent hose from the
moulded plastic fuel tank filler neck as
(a) On Saloon and Hatchback models, reach up into the right-hand side aperture in the rear suspension crossmember, slacken the clamp, and work the hose off the filler neck stub. This is a job for someone with small hands, good tools and a lot of patience! (see illustration).
10.7A Fuel filler vent hose clamp (arrowed) is accessible through right-hand side aperture in rear suspension crossmember on Saloon and Hatchback models . . .
(b) On Estate models, slacken the clamp immediately above the rear anti-roll bar, and work the hose off the filler neck stub (see illustration).
10.7B . . . on Estate models, it is immediately above rear suspension anti-roll bar
8 Unscrew the six retaining nuts, and withdraw the exhaust system’s rear heat shield from the underbody (see illustration).
10.8 Exhaust system must be lowered and heat shield removed to enable fuel tank removal - arrows show location of retaining strap front bolts
9 Support the tank with a trolley jack or similar. Place a sturdy plank between the support and the tank, to protect the tank.
10 Unscrew the bolt at the front of each retaining strap, and pivot them down until they are hanging out of the way. Note the earth lead under the left-hand strap’s bolt - clean the mating surfaces before the tank is refitted, so that clean, metal-to-metal contact is ensured.
11 Lower the tank enough to unclip the fuel return pipe (coded red) from its top surface, then disconnect the charcoal canister’s vapour hose from the union at the top rear of the tank (see illustration). If you have any doubts, clearly label the fuel lines and hoses, and their respective unions. Plug the hoses, to prevent leakage and contamination of the fuel system.
10.11 Lower fuel tank - do not distort filler neck stub (A) - and unclip (red-coded) fuel return pipe (B), then disconnect charcoal canister’s vapour hose (C)
12 Remove the tank from the vehicle, releasing it from the filler neck stub. While the tank is removed, unhook the retaining straps (twist them through 90° to do so), and check that they and their locations in the underbody are in good condition.
13 With the fuel tank removed, the filler neck can be withdrawn. It is secured by a single screw in the filler opening, and by two bolts to the underbody.
14 Refitting is the reverse of the removal procedure.