All about Ford Mondeo

Fuel filter renewal (Every 60 000 miles)
Routine maintenance and servicing / Fuel filter renewal (Every 60 000 miles)


Warning: Petrol is extremely flammable, so extra precautions must be taken when working on any part of the fuel system. Do not smoke, or allow open flames or bare light bulbs, near the work area. Also, do not work in a garage if a gas appliance with a pilot light is present. While performing any work on the fuel system, wear safety glasses, and have a suitable (Class B) fire extinguisher on hand. If you spill any fuel on your skin, rinse it off immediately with soap and water.

1 The fuel filter is located at the front righthand corner of the fuel tank, just forward of the vehicleТs right-hand rear jacking point. The filter performs a vital role in keeping dirt and other foreign matter out of the fuel system, and so must be renewed at regular intervals, or whenever you have reason to suspect that it may be clogged. It is always unpleasant working under a vehicle - pressure-washing or hosing clean the underbody in the filterТs vicinity will make working conditions more tolerable, and will reduce the risk of getting dirt into the fuel system.

2 Relieve any residual pressure in the system by removing the fuel pump fuse (No 14) and starting the engine; allow the engine to idle until it dies. Turn the engine over once or twice on the starter, to ensure that all pressure is released, then switch off the ignition.

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

3 Noting the comments made in Section 1 of Chapter 5, disconnect the battery earth terminal.

4 Jack up the rear right-hand side of the vehicle, and support it securely on an axle stand.

5 Using rag to soak up any spilt fuel, release the fuel feed and outlet pipe unions from the filter, by squeezing together the protruding locking lugs on each union, and carefully pulling the union off the filter stub (see illustration). Where the unions are colourcoded, the feed and outlet pipes cannot be confused; where both unions are the same colour, note carefully which pipe is connected to which filter stub, and ensure that they are correctly reconnected on refitting.

33.5 Squeeze together fuel filter pipe union locking lugs, then pull pipes
33.5 Squeeze together fuel filter pipe union locking lugs, then pull pipes off filter stubs - ensure pipes are correctly reconnected

6 Noting the arrows and/or other markings on the filter showing the direction of fuel flow (towards the engine), slacken the filter clamp screw and withdraw the filter. Note that the filter will still contain fuel; care should be taken, to avoid spillage and to minimise the risk of fire.

7 On installation, slide the filter into its clamp so that the arrow marked on it faces the correct way, then slide each pipe union on to its (correct) respective filter stub, and press it down until the locking lugs click into their groove (see illustrations). Tighten the clamp screw carefully, until the filter is just prevented from moving; do not overtighten the clamp screw, or the filter casing may be crushed.

33.7A When installing the new filter, ensure the arrow showing direction of
33.7A When installing the new filter, ensure the arrow showing direction of fuel flow points towards the engine . . .

33.7B . . . secure pipe unions as described - do not overtighten clamp screw
33.7B . . . secure pipe unions as described - do not overtighten clamp screw (arrowed)

8 Refit the fuel pump fuse and reconnect the battery earth terminal, then switch the ignition on and off five times, to pressurise the system. Check for any sign of fuel leakage around the filter unions before lowering the vehicle to the ground and starting the engine.


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