DIY ford mondeo 3 fuel pump repair

The fuel systems of modern injection vehicles are very sensitive to fuel quality and purity. And with these matters, as you know, not always and not everywhere everything is in order. Ford Mondeo 3, as one of the best European representatives of Ford Motors, has not easily and painfully adapted to the post-Soviet operating conditions since its inception. First of all, the fuel system of the car suffered, and it was not easy to find out about the malfunctions from habit.

The most vulnerable parts of the power supply system of the Ford Mondeo 3 injection engine are fuel injectors and a fuel pump. With the nozzles, it is more or less clear when they are clogged, even a child understands that cleaning is necessary and it is better than ultrasound therapy until nothing has been invented. It is possible to determine that the nozzles are clogged without diagnostic equipment. First, the Jackie Chan control lamp (Check-Engine) will immediately report engine malfunctions. And secondly, the unstable operation of the engine at idle and transient modes, heavy start-up and increased fuel consumption will leave no doubt. Clogged nozzles can almost always be saved by cleaning, but we strongly do not recommend using a variety of fuel additives, especially domestic ones, to clean the power system. They can bring some benefit before the sale of the car, but they add problems to the new owner. The best option is mechanical or ultrasonic cleaning.

Let's not get distracted and return to the gas pump. And we were distracted for a reason, since we need to distinguish clogged nozzles from a dying pump. Moreover, the Ford pump does not die immediately, but gives distress signals long before it finally fails. Symptoms are very similar to those given by injectors, but the main reason for the pressure drop in the rail is still different. With clogged injectors, measuring the pressure on the rail can show a full rate. On pre-styling Ford Mondeos, the pressure could be measured directly on the ramp using a pressure gauge and a fitting. After restyling, this possibility disappeared, so it became more difficult to determine the malfunction. Nevertheless, it is possible to measure the pump pressure, but already directly in the line, and best of all, right next to the gas pump, by including a pressure gauge in the gap between the output fuel circuit and the gas pump itself.

To summarize, the reasons why you should think about replacing the gas pump are as follows:

1. Difficult cold start.
2. Deterioration in dynamics.
3. Jerks in transient conditions.
4. Unstable idle speed.
5. Increased fuel consumption.

And, as a confirmation of the diagnosis, the noise of the pump during operation and the low pressure in the fuel system will make it clear that the 200 thousand km that the plant guaranteed (reliable operation of the pump) passed without a trace. Even though the odometer can show a much lower mileage. Bad gasoline has done its job, therefore, whatever one may say, the fuel pump on the Ford Mondeo 3 must be replaced.

Ford engineers somehow overestimated the capabilities of their pump, or our fuel is of such poor quality that the resource of the unit, in comparison with the passport, can be halved. That is why it never occurred to the engineers that you and I would have to get the pump out quite often. Either for cleaning and replacing the meshes of the primary filter, or even for dismantling the entire fuel module, as this time. They hid the pump in the fuel module, and put the whole economy in the gas tank. Now you can get to the node only in two ways, one of which is correct, and the second is practical.

According to science, replacing a gas pump with a Ford Mondeo 3 takes place only after removing the gas tank. For obvious reasons, everyone tries to avoid this procedure for as long as possible, because the officials, in addition to replacing the module itself, add a bunch of necessary options, so as much as it costs to remove and change the pump from a dealer, a new fuel rail will cost along with pump, module, and sometimes even with nozzles. Depending on the pretentiousness of the dealer, this procedure will require at least 5000 rubles, which, you see, is immodest on their part.

That is why you will have to do the work with barbaric methods, and without removing the tank. You have to work hard, but it's worth it.

1. Remove the rear seat, remove the mats and get to the plug with the wires and the fuel line.
2. Remove the plug, carefully, without damaging the wires and fuel line.
3. Cut a hatch close to a round one with scissors for metal, gradually expanding the existing hatch until it becomes possible to dismantle the fuel module and, along with it, the motor on the gas pump.
4. Then turn the pump counterclockwise and disengage it from the gas tank.
5. Disconnect the commutation.
6. Dismantle the fuel pump.

This is the only way to get the fuel module on the Ford Mondeo 3 without removing the tank. But the pump may still be very good, because the pre-filter mesh could simply clog. In any case, the car plant considers the fuel module to be a non-separable part and it will be necessary to change the electric motor of the fuel pump to a Ford Mondeo at its own peril and risk.

After the new fuel pump is installed and the commutation is connected, it is necessary to find a replacement for the hatch, which is no longer suitable. You can cut the cover out of hard plastic or textolite by placing it on self-tapping screws and sealing the activity with porous foam on an adhesive basis or any other sheet sealant.

Part one, practical
Why not theoretical? This is the more important part for the average man in the street.
Location in the fuel tank. You can see exactly where by lifting the back seat.
In the station wagon and heche, the seat just rises to a vertical position, in the sedan it will have to be removed .. The seat is attached with two clips - just pull up You see exactly in the middle a black rubber plug with a protruding wire - w / n right under the plug.
How to get it? there are only two ways:

1. Remove the fuel tank according to the service manual
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2. Increase the opening under the rear seat;

2-1. Why do you need metal scissors (if you are left-handed, no problem, there is a tool for you)

2-2. We take out the rubber plug and remove the connector from the gas pump (well, it's clear here) and, armed with a tool, we cut

2-3. As a result of this act, you will get such a squiggle. I post a photo in a special way so that you realize that the size of the cropped area is not coaxial with the hole

2-4. And the result of the work will be a neat or not very (depending on your efforts) hole. like this

IMPORTANT! When working with scissors, be careful not to accidentally cut the fuel lines.
If this does happen: Order numbers 1152659 - red (according to the collet ring color) 1328926 - White
How to dismantle a pump - there are many options. It all depends on your imagination and capabilities, but the first thing to do is to find out:

How to do it right; disconnect the fuel lines - this is described here
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In general, I take the pliers, scroll the fitting 5-10 degrees to the left / right, loosen the compression - I press the ring with the pliers with the pliers, squeeze and pull it out again

Note: if you have torn rubber rings on the gas pipe fastening fittings, the pump repair kit 33.1111058 or 2531112015 from KAMAZ will help you (it is unlikely that it will be needed if you followed the recommendations for removing the lines and did not pull out the fitting locks from the pump body)

IMPORTANT!
Before performing this operation, release the pressure in the fuel line,
start the engine (I hope you disconnected the chip) and let it stall, disconnect the fuel lines.
Be extremely careful - the edges of the flap you expanded are very sharp.
I am specially attaching a photo - PLEASE NOTE - the retaining rings remain in the case - ONLY SO and not otherwise, even when you collect everything back - just insert the gas pipe fittings

Second: How to unscrew the nut - there are three most convenient ways (the rest are the flight of your imagination):
1. Make a special key (this method is most likely for aesthetes)

2... Dissolve the handles of the scissors with which you cut your Mondeo so that they reliably rest against the edges of the nut, then grab the cutting part of the scissors with an adjustable wrench and unscrew the nut counterclockwise

3. (I personally (Lexsus) use this method: take a wooden lath 2x2 cm and a length of about 30 cm and with its help, resting the end of the lath on the edge of the nut and helping with a hammer knock the nut off - no aesthetics, but practical - everything that is needed under hand ..

Note from Zhish
To correctly install the t / pump mounting ring, after finishing work on the pump, lubricate its threads with grease (graphite, for example). On the side surface of the ring there is a triangle stamping with the top down of the ring. For the correct installation of the ring on the thread of the t / tank, you need to combine this vertex of the triangle with the vertex of the same name on the t / tank itself. Then the ring will immediately go along the thread.
We remember the location of the pump in the tank.

We lower both hands into the tank, grab the glass so as not to damage the level sensor and, with some effort, turn the glass counterclockwise by thirty degrees. The pump has been dismantled. The photo below shows the bottom of the tank with the fuel pump mounting bracket, by the way, note that the owner of this hatch carefully processed the edges with a rubber hose cut along the length

Before removing the module from the tank, try to drain the fuel out of the
glasses through the slots in the glass lid.
We take out the pump module assembly.

His number: Bosch 0 986 580 406, for engines 1.8-2.0
Analogues: AIRTEX E10546M
Messmer: 775183 (ATTENTION! This pump has a lot of complaints, so this option is the most extreme case)
Bosch: 0 986 580 408, for engines 2.5
Analogues: Messmer 775188
ERA - 775188 - Fuel pump - 1117945-1119881 - fuel pump FORORD MONDEO III 2.5 V6 24V 00 assy
ERA -775183 - Fuel pump (complete) FORD Mondeo III 1,8 / 2,0L 00-07 (3,8 bar)

Before proceeding with the disassembly of the pump, we separate the fuel sensor, be careful with this device, it is quite fragile, it is easy to break or bend it, but then you will not be concerned with false readings of the fuel level. (in the photo the sensor clip)

Now, armed with a pair of flat-blade screwdrivers, we begin to release the latches around the circumference of the gas pump glass and divide it into two halves

Upper (in the photo there is a pump with a large filter, which no one has yet been able to find to replace, more often a triangular bast shoe

The lower part, the so-called glass

Actually the pump itself is already separate (it is simply pulled out from the top cover)
Bosch 0 580 453 417 for engines 1.8-2.0
Or an analogue from SPART (USA) cat. room FP1013 no alterations needed
Bosch 0 580 453 449 for engines 2.5

And almost the last part is the filter itself (bast shoe), its number from the focus 107 13 23

And a very nice complement from maratrix
A coarse mesh for a gasoline pump fits Spart, cat. no. FPS145 I tried it on a Spart FP1013 gas pump - it fits perfectly! The most remarkable thing is that this bast shoe costs about 80 rubles in Existe.

Part two, technical data, some theory, symptoms and reasons for refusal

Symptoms:
The car dulls, the engine does not develop full power, this is especially noticeable when picking up speed and reducing the speed limit as such
Pressure in the fuel system after the fuel filter:
With the engine running -
1.8-2.0 3.9bar, min 3.7bar, max 4.2bar (capacity 63l / h)
2.5-3.0 4.5bar, min 4.2bar, max 4.7bar (capacity - 74l / h)
10 minutes after turning off the ignition -
1.8-2.0 not less than 2.5bar
2.5-3.0 not less than 3.2bar.
How to check - measure the pressure, there are two options:

2. Restayl - pressure gauge, can be connected only in the gap, between the fuel filter and the rail

In both cases, without special devices, it will not be possible to connect a pressure gauge to the system.

The adapter is made from an old Soviet cap to the camera - it has a long threaded part and a through hole plugged with a rubber stopper (remove it). The adapter design is shown in Fig. sixteen
However, this check is not 100%, this is only an indirect confirmation of the malfunction .. The first thing you should do in case of unsatisfactory results is to change the fuel filter (located in front of the rear right wheel - below)

About the filter here:
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After replacing the fuel filter, repeat the procedure.

Who is the blue - ejector (jet) pump at the bottom of the glass
Symptoms: the same as in the previous post + it does not start well if there is less than a third of the gas in the tank + it may not start at all if the car is on an uphill
Its main purpose is to be responsible for the fullness of the poured glass, I write about this without a drop of irony. The fact is that our electric pump stands vertically in the tank, the intake filter mesh sticks up the same, if it works correctly, it (the mesh) must be constantly in gasoline, otherwise it will be easier for the pump to pump air - hence the pressure drop in the fuel line with all flowing out .. Meanwhile, there can be both a maximum and a minimum of gasoline in the tank, and the glass must always be full, this is what the blue pump provides

A little about the main malfunctions of the fuel pump modules:
(Hereinafter, quotes from forum materials)
vova - “Blue has a fault not in a clogged nozzle, but just the opposite - its defect is a greatly enlarged hole! As it turned out, the normal size of the jet for the new pump is 0.2-0.25 mm.
As soon as the plastic is cut by a jet of gasoline by one tenth of a radius, the khan comes to the pump. With a nozzle diameter of 0.5 mm or more, half of the gasoline that is pumped by the main pump goes uselessly into this ejector. The engine starts to run out of fuel. " How temporary measure, and in some cases this is a rather long period of operation, cleaning or replacing the filter (s) in the fuel pump module and muffling the blue helps, but you should remember:
vova: - " My opinion. Dull in the heat - cleaning or replacing the filter (filters), it did not help - replacing the module assembly ”. And if you have drowned out the blue, then the fuel tank should always be. not less than 1/3 of the fuel level, because the fullness of the poured glass, which was mentioned above, is no longer there.
By the way, here is a pictorial photo of a muffled pump

How to wash filters?
Well, now there are plenty of all kinds of chemistry, but as a theme editor (Lexsus) I dare to offer a radical (read effective) method available to everyone.
Take a half-liter jar (preferably with a lid) pour water with a temperature of 50 degrees, add one and a half to two tablespoons of washing powder and finally the filter itself .. From time to time you chatter the can, after about an hour our filter is clean, it remains to rinse and dry .. Believe me - look practically a new filter is provided for you

The causes of the malfunction are encountered, much less often - the pump does not show signs of life at all (does not buzz), the fuse is constantly on (No. 27 at 15 A in the engine compartment) or the pressure in the rail is much higher than normal.

There are only three of them:
1. Burning of the terminals (contacts) of the main pump (insert), as a rule, this is observed on the black wire

In this case, you need to clean the terminals (what is left) on the insert, measure the resistance of the windings and if it is normal, continue using it and save money for a new one.
As a rule, the plug (which is on the wires) cannot be reused, it must be removed, the wires must be stripped and new terminals crimped, insulating the open parts with heat shrinkage.
In fairness, it is worth mentioning the burning of the terminals on the fuel pump module chip, the one that you remove during dismantling (white 4-pin)

2. Turn-to-turn closure.
Zeng: - "The resistance of the windings of the insert is less than 4 ohms - go to the trash heap."

3. Stuck pressure relief valve

Note: “It looks like the fuel pressure regulator is covered, which is screwed with 3 torxes to the body of the fuel pump, tell me if it is really possible to replace it and what can anyone know the code for - I ate 20 liters, today changed it to RDT-380 from VAZ21124 and consumption up to 12 liters. It does not have fasteners, it is placed under the cover on 3 self-tapping screws on the pump housing, the only thing that the VAZ regulator has on the body is some kind of pin welded by spot welding, but it breaks off perfectly with planes and a screwdriver. His pressure is 3.8 which I think is quite acceptable for a Mondeo 2.0 ″

And finally, about checking the fuel pump itself (motor)

Attention! This check FIRE DANGEROUS!- be extremely careful !:

Plantation Daddy:
“In order to make sure that even a new pump is 100% suitable, it is necessary to measure its head separately from the system directly at the outlet of it. In this case, the following relationships are valid:
10 m of water column = 1 bar = 100,000 Pa = 100 kPa
in the slang of hydraulics, this is called "measuring the pressure in the wall"
At home, you will need a container with gasoline, a pressure gauge designed for at least 10 bar, charged with a battery

Having built on COLLARS and SHORT! hoses an uncomplicated small design: a gas pump-hose-pressure gauge
1. The head pressure of the working pump must be 7.5 bar
2. The head pressure must appear instantly "

Prepared on the basis of the topic: "Your favorite gas pump, who put what, and what is the result?"

If fuel from the gas tank stops flowing to the engine, the car will not go far. This applies to all machines. Fort Mondeo is no exception. Disruption of the fuel supply to the engine can occur for various reasons. But the most common is the breakdown of the fuel pump. If this happens, the owner of a Ford Mondeo car does not need to go to a car service. You can replace the fuel pump on your own, and you don't even have to remove the gas tank for this. Let's figure out exactly how this is done.

As you know, Ford Mondeo cars have been subjected to so-called restyling more than once. To date, four generations of these machines have already been replaced. Restyling of the first three generations of cars mainly affected their bodies and interiors.

Noise and thermal insulation was improved, the shape of the radiator grilles and dashboards was slightly changed. There were no significant changes in the engine and chassis. These changes appeared only in the fourth generation Ford Mondeo. But not a single restyling has affected the actual fuel pumps. So the fourth generation pump is no different from the first generation pump.

Fuel pumps on a Ford Mondeo can differ only in their principle of operation. They can be:

The first ones are installed on cars with a carburetor engine, the second ones - on cars with an injection fuel injection system. But even this difference does not change either the location of the fuel pumps in Ford Mondeo cars, or the system of their fastening.

The main manufacturer of fuel pumps for Ford Mondeo cars is the Ford Motor Company. In our country, these parts are manufactured at the Ford plant in the city of Vsevolozhsk. Gas pumps for Ford Mondeo are also produced by third-party manufacturers, such as VDO, BOSCH, Valeo, VAICO, Pierburg, etc. It should also be noted that the cost of original Ford pumps is always slightly higher compared to other manufacturers.

The fuel pump is located under the floor of the passenger compartment, right under the feet of passengers sitting in the back seat of the car. There is a small hole above the pump, covered with a plug. The problem is, it's too small. And it is not possible to remove the fuel pump through this hole.

Before proceeding to the description of the pump dismantling process, one important clarification should be made. As mentioned above, the fuel pump is located under the floor of the passenger compartment, but it is impossible to remove it through the standard opening. The official instructions say that to replace the fuel pump, the car owner will have to completely remove the gas tank. This is a very difficult and time-consuming procedure, which not everyone can do. Therefore, domestic motorists have found a way to remove the gas pump without removing the gas tank. This method is not aesthetically pleasing, but it is effective and takes a minimum of time. For this reason, it is he who will be considered below. But first, let's decide on the tools that will be needed for work.

1. The rear door of the passenger compartment is opened, the rear seat is removed, the carpet is removed from the floor.Access to a metal plug is opened, under which there are fuel lines and a pump.

1. Before disassembling a fuel pump removed from a standard niche, it is necessary to disconnect the fuel sensor from it. This is done with pliers (extreme care should be taken when performing this operation: the sensor is very fragile).

• before removing the fuel pump, it is highly advisable to drain all the gasoline from the gas tank. This is not done by everyone and not always, however, a complete drain of the fuel will make all further work much safer;
• cut the hole in the floor with scissors only. In no case should you use a chisel or grinder. Any spark from these tools can cause fire and explosion;
• When cutting through the floor covering, care should be taken as it can easily damage or completely cut the fuel hoses;
• all work must be carried out in a well-ventilated area, and ideally in the open air;
• there should be no open sources of ignition near the vehicle. During work, you should refrain from smoking and be sure to keep a fire extinguisher on hand;
• if something needs to be illuminated in the cabin, you should only use an electric flashlight. The use of matches or lighters is strictly prohibited;
• all work should be done with goggles and protective rubber gloves;
• before disconnecting the hoses of the fuel lines, put a few pieces of rags on the fuel pump cover. Despite the release of pressure in the system, gasoline still remains in the fuel hoses. And it can flood the floor of the cabin.

So, in order to remove the gas pump, you do not need to blindly follow the instructions. Sometimes you can turn on your ingenuity and thereby save yourself from a serious headache that will inevitably arise if a motorist tries to remove the gas tank from the Ford Mondeo alone. And of course, when dealing with gasoline, in no case should we forget about safety measures and personal protective equipment.

Ford Mondeo cars have been produced since 1993 - during this time, four generations of models have already appeared. All of them are united by quality of workmanship, stylish design and reliability in operation. At the moment, a large number of car owners are interested in the characteristics of the fuel pump of the "Mondeo" fuel system and the procedure for replacing a failed device. After all, servicing a foreign car in a service station is not cheap, so many owners want to learn how to perform specific procedures with their own hands.

Ford Mondeo cars are equipped with high-quality and reliable fuel pumps during the production process. However, during operation, it may be necessary to replace this device.

It should be noted that the engines of all the latest generations of "Mondeo" have a characteristic feature: the gas pump installed on them is equipped with an emergency system that will turn off the fuel supply to the engine in case of an accident. The system is equipped with sensitive sensors that are immediately triggered by a sharp push or head-on impact. Thus, in the event of an accident at a Ford Mondeo, there is a better chance of surviving.

Regardless of the year of manufacture of the car, a wide variety of electric-type gasoline pumps can be installed on it. Fuel pumps from the following manufacturers are optimally suited for Ford Mondeo:

• Bosch - pump with increased service life;
• Pierburg - pump with changeover valves;
• Era - the device is unpretentious in operation and does not require special maintenance;
• Messmer is one of the most budget-friendly fuel pump options for Ford Mondeo cars.

The devices of the German manufacturer are known for their quality and reliability.

When selecting a gasoline pump, remember that the operating range of the device should not exceed 4.0–4.1 bar in the system.

Italian manufacturer of pumping equipment for cars

Due to the fact that injection engines are used on all generations of Ford Mondeo cars, it is advisable to use an electric fuel pump.The essence of its work is to pass the required amount of fuel through itself and send it to the engine.

An electric fuel pump is entirely dependent on the operation of the solenoid valve. However, during prolonged operation and driving without stopping, the valve itself and the elements located in the pump housing become very hot. Therefore, in order to cool the pump and prevent it from overheating, the device is installed directly in the fuel tank. The gasoline helps the pump cool down.

Thus, the fuel pump on all Ford Mondeo models is mounted in the gas tank itself for ease of operation and an increase in the resource of the device.

The fuel tank hatch is located under the rear seat of the "Ford Mondeo"

According to the owners of the car, the fuel pump can be considered one of the vulnerabilities of the Fords. It can fail at any time, regardless of the driving conditions and the nature of the machine's maintenance.

At the same time, the cost of a new device for many drivers is very high: depending on the manufacturer, a gas pump can cost from 12 thousand rubles.

For "Ford" is characterized by the premature death of the fuel pump, which is due to its practical maintenance-free! The filter does not change separately, etc. This is a problem, but FMK persists! A person (waiting), buying a car for 15 and above kbps, wants pleasure with this money! And then everything pops up when the run is funny! Comparison with "Zhiguli" is incorrect, because TAZ is definitely more economically profitable than FF2! Sleep well for 4 years will not work, because soon the brake discs will fail (they are soft in FF2), etc., and the cases are out of warranty! By the way, there used to be dealers' refusals to carry out warranty repairs of gasoline pumps: “Pour bad gasoline! Ford has nothing to do with it! Give me quality! "

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As a matter of fact, the very procedure of replacing the fuel pump on Mondeo cars is not pleasant and easy. In the operating manual, the manufacturer makes it clear that the device can only be replaced when the fuel tank is completely removed. Therefore, the procedure can be delayed for a long time and will require from the motorist not only skill, but also physical strength.

However, there is a way to simplify the procedure for replacing the fuel pump and to carry out this operation without removing the tank capacity with gasoline.

As mentioned above, the device itself is located in a gas tank. The tank is located under the rear seats in the passenger compartment. If you lift the seat cushion, it is easy to see the plug with the wire. The contact part of the pump (plug with wires) can be removed immediately with a flat screwdriver.

The pump is placed in the gas tank and can be accessed through the passenger compartment.

This is access to the pump itself. Opening the plug with a regular flat screwdriver, you can immediately make sure that the gas pump does not crawl into the existing hole. This problem is solved quickly enough.

So, in order to replace the pump with a new one and not waste time dismantling and installing the fuel tank, it is recommended to immediately prepare the necessary set of tools:

• scissors for metal;
• marker or felt-tip pen;
• masking tape.

In the process of work, it is very important to follow the rules of personal safety. These notes will help to simplify the replacement procedure as much as possible and facilitate the main stages of work:

1. It is more advisable to drain all gasoline from the tank in advance.
2. For cutting metal, it is not recommended to use electric cutting tools such as a grinder, as sparks from it can enter the fuel droplets and ignite.
3. Be extremely careful not to damage the wires and hoses.
4. It is recommended to reduce the pressure in the system before disconnecting the fuel lines. It is enough to remove the chip from the fuel pump and start the car. The engine uses all the fuel in the system and will stall by itself.

Smoking is strictly prohibited during operation!

To achieve the desired result, follow the following algorithm:

1. After the plug under the rear seat of the "Ford Mondeo" has been opened, you will need to take metal scissors and start expanding the hole so that the gas pump can crawl into it.
2. To make the hole more or less even, it is best to first draw its outline on the metal surface with a felt-tip pen.
3. After making the hole, you can take out the pump itself. Before that, it is recommended to seal the sharp edges of the hole with masking tape so as not to injure your hands.

Thus, the procedure for dismantling the fuel pump is not a problem. The only caveat is that you need to be able to work with scissors for metal.

Working with scissors for metal is very painstaking

The installation of a new device instead of the dismantled one is carried out in the following sequence:

The connection of the fuel pipes and wires is reversed.

1. The fuel pump is connected in the reverse order.
2. The fuel lines are connected to each other through connectors.
3. After the installation work, it will be necessary to decide what to do with the cut hole. Each car owner will have his own solution to this issue: you can install a home-made cover on it, or simply seal it with masking tape. The main thing is to make sure that no debris and dirt gets inside the tank, and it does not matter in what way you will achieve this.