Check the fuel pressure first (see Checking the pressure in the engine fuel 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, and a container to drain the 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 it is not possible to access it with the tank installed on the vehicle.
2. Pry up the fuel module wiring harness connector retainer…
3….and disconnect the connector 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 using 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 fuel level indicator sensor float, and drain the fuel from it into a pre-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 O-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 up the fuel module wiring harness connector…
14….and disconnect it from the terminals of the module body.
15. Pry up 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 housing.
18. Pry up the fuel pump module cup retainers…
19….and remove the glass from the module.
20. Pry off the fasteners of the fine fuel filter…
21….and remove the filter from the fuel module.
22. Pry up the 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 retainers…
26….and remove it from the fuel module.
27. Pry off the fuel drain hose tip retainers…
28….and remove the hose tip from the fuel pressure regulator.
29. Assemble and install the fuel module in the reverse order of removal.