Fuel quantity sensor, fuel pump removal and installation (Mondeo 1)

The fuel level sensor is installed in the tank from above. In gasoline engines, the fuel pump is located on the bracket of the fuel level sensor. If the fuel level in the tank drops, the float of the fuel level sensor in the tank also drops. Due to the sliding contact on the float, the electrical resistance of the sensor increases. As a result, the voltage on the indicator drops, and the indicator arrow moves in the direction of "empty".

The fuel level sensor should be checked if the indicator on the instrument panel shows an incorrect amount of fuel.

Prerequisites for checking: check all electrical wires according to the electrical diagrams, see item 20.4.

Warning! Ensure good ventilation of the workplace. Fuel vapors are toxic, do not use open flame, flammable! Keep a fire extinguisher at hand.

Removal

Disconnect the negative (-) cable from the battery.

Warning! This will erase data in electronic memory devices, such as the engine fault memory device or the radio code. Please read the section carefully "Removing and installing the battery", before disconnecting it.

All wheel drive models: There are two fuel quantity sensors/fuel pumps. To remove, remove the fuel tank, see p. 5.3.

Front wheel drive models: Remove the cushions from the rear seat, see paragraph 17.34.

Remove the rubber caps and disconnect the multi-pin plug.

Disconnect the fuel supply and return lines from the fuel tank. To remove the clamp, fully depress both buttons on the quick release and remove it.

Warning! The fuel system in gasoline engines is under pressure. Collect fuel leaking from open fuel lines with a rag. Before removing the fuel lines, mark them with adhesive tape to avoid confusion when connecting.

Unscrew the fuel tank bracket counterclockwise using a special tool from Ford 23-038. If you do not have such a tool, then the fuel level sensor in the tank can be removed using a pipe wrench or a hard wooden rod, lightly tapping it with a hammer.

Caution! Avoid sparks - fire hazard!

Pull the fuel level sensor bracket up, move it aside and remove it. Place a rag underneath it and collect any leaking fuel.

Installation

Check the sealing surfaces of the receiver and the bracket of the fuel level sensor in the tank, clean them from rust and dirt.

Caution! No dirt should get into the fuel tank.

Install the fuel tank sensor bracket with a new seal, tighten it by turning it clockwise. Connect the multi-pin plug.

4WD models: Install fuel tank, see p. 5.3.

Connect the fuel supply and return lines. Do not mix up the connections. Make sure the quick release fasteners are pushed onto the hoses up to the flange.



Insert the rubber pads into the bottom of the car and install the rear seat.

Connect the ground wire to the battery. Set the clock and set the radio anti-theft code.

Check the functions of the fuel indicator on the instrument panel.

(The original can be found on the specified resource: Fordbook.ru)