Replacing the fuel pump (Fusion)

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If the engine power drops, there is increased noise, or you can periodically hear howling sounds when the fuel pump is running, then most likely the fuel pump is out of order.

Pre-check the fuel pressure in the fuel supply system as follows.

1. Check the serviceability of the fuel pressure regulator (see "Checking and replacing the fuel pressure regulator").

2. If the system pressure is less than 250 kPa (2.5 kgf/cm²), replace the fuel filter (see "Replacing the fuel filter").

If the pressure does not increase in this case, the fuel pump must be replaced, since the pump has a difficult-to-disassemble design and its components are not supplied separately as spare parts.

You will need: a flat-blade screwdriver, a container for draining fuel from the fuel pump module.

1. Reduce the pressure in the fuel system (see "Reducing pressure in the fuel system").

2. Disconnect the wire from the negative terminal of the battery.

3. Remove the fuel tank (see "Replacing the fuel tank").

3. Remove the fuel tank (see «Replacing the fuel tank»).


4. Unscrew the fuel pump module retaining ring by positioning the pliers handles as shown in the photo…

4. Unscrew the fuel pump module retaining ring by positioning the pliers handles as shown in the…


5. …and remove the ring.



5. …and remove the ring.


6. Carefully remove the fuel pump module and drain the fuel from it into a previously prepared container.

6. Carefully remove the fuel pump module and drain the fuel from it into a previously prepared…


7. Remove the sealing gasket.

Note: Be sure to replace the gasket if it is torn or severely compressed.


Note: Be sure to replace the gasket if it is torn or severely compressed.


8. Disconnect the connector from the terminal on the fuel pump module housing cover...

8. Disconnect the connector from the terminal on the fuel pump module housing cover...


9. …and from the fuel level sensor.



9. …and from the fuel level sensor.


10. Squeeze the ends of the retainer and remove the fuel level sensor.

10. Squeeze the ends of the retainer and remove the fuel level sensor.


11. Use a screwdriver to press the fasteners on the fuel pump module housing…

11. Use a screwdriver to press the fasteners on the fuel pump module housing…


12. …one clamp inside…

12. …one clamp inside…


13. …and disconnect the fuel pump module housing.



13. …and disconnect the fuel pump module housing.


14. Remove the spacer half ring.

14. Remove the spacer half ring.


15. Use a screwdriver to pry…

15. Use a screwdriver to pry…


16. …and remove the filter from the pump.

16. …and remove the filter from the pump.


Note: Carefully inspect the filter for mechanical damage and contamination, if necessary, wash or replace the fuel intake filter.




Note: Carefully inspect the filter for mechanical damage and contamination, if necessary, wash or…


17. Disconnect the wiring harness connector from the fuel pump.

17. Disconnect the wiring harness connector from the fuel pump.


18. Loosen the clamp securing the hose to the fuel pump pipe and remove the fuel pump.

Note: The hose clamp is disposable, please replace it with a new one during assembly.


19. Assemble and install the fuel pump module in the reverse order of removal.

19. Assemble and install the fuel pump module in the reverse order of removal.


Note: To make installation of the pressure ring easier, apply a small amount of silicone grease to the inside of the pressure ring.




Note: To make installation of the pressure ring easier, apply a small amount of silicone grease to…


Note: When installing the module, make sure that the marks on the fuel tank, the retaining ring and the fuel pump module housing are aligned.


The original can be found on the specified resource (fordbook)






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