🔧 Fusion - Fuel Pump Replacement

Replacing the fuel pump on your Fusion requires lowering the fuel tank because the pump module is mounted inside the tank. This job involves gasoline, fuel vapor, and working under the vehicle, so take your time and follow the safety steps carefully.

Difficulty Level: Advanced | Estimated Time: 4-6 hours

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⚠️ Safety & Precautions

• ⚠️ Gasoline vapors are extremely flammable. Work outside or in a very well-ventilated area away from sparks, heaters, cigarettes, and open flames.
• ⚠️ Keep a Class B fire extinguisher nearby before opening the fuel system.
• ⚠️ Relieve fuel pressure before disconnecting any fuel lines.
• ⚠️ Disconnect the negative battery cable before lowering the tank.
• ⚠️ Support the fuel tank with a transmission jack or floor jack and wood block before removing tank straps.
• ⚠️ A nearly empty tank is much safer and easier to handle. Drain or drive the vehicle until the tank is below 1/4 full before starting.
• ⚠️ Do not use power tools near open fuel vapors or fuel lines.

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🔧 Required Tools

You'll need the following tools for this repair:

• Safety glasses
• Nitrile gloves
• Class B fire extinguisher
• Wheel chocks
• Floor jack rated 3-ton minimum
• Jack stands rated 3-ton minimum
• Transmission jack (specialty)
• Wood block 12-inch
• Fuel line disconnect tool set (specialty)
• Fuel pressure gauge with Ford adapter (specialty)
• Fuel-safe drain pan 2-gallon
• Ratchet 3/8-inch drive
• Socket set 8mm-15mm
• Extension 3/8-inch drive 6-inch
• Torque wrench 3/8-inch drive inch-pound
• Torque wrench 3/8-inch drive foot-pound
• Flathead screwdriver 1/4-inch
• Trim clip removal tool
• Brass drift punch (specialty)
• Non-sparking hammer (specialty)
• Shop towels
• Marker pen

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Fuel pump module assembly - Qty: 1
• Fuel pump tank seal O-ring - Qty: 1
• Fuel pump lock ring - Qty: 1
• Fuel line retaining clips - Qty: As needed
• Fuel tank strap bolts - Qty: As needed
• Gasoline-safe cleaner - Qty: 1

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📋 Before You Begin

• Park your Fusion on level ground outside or in a well-ventilated workspace.
• Set the parking brake and place wheel chocks at the front wheels.
• Make sure the fuel level is below 1/4 tank.
• A fuel line disconnect tool releases spring-lock fuel fittings without breaking the connector.
• A brass drift punch is a soft metal punch used to turn the fuel pump lock ring without creating sparks.
• Do not use steel punches or regular hammers on the fuel pump lock ring.
• Factory torque values can vary by fastener design. If a replacement part includes updated instructions, follow the instructions supplied with that part.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Relieve fuel system pressure

• Open the hood and put on safety glasses and nitrile gloves.
• Use the interior fuse panel or underhood fuse panel diagram to locate the fuel pump fuse or relay.
• Use the trim clip removal tool or your fingers to remove the fuse panel cover.
• Pull the fuel pump fuse or relay by hand.
• Start the engine and let it run until it stalls.
• Crank the engine for 3-5 seconds more to bleed off remaining pressure.
• Turn the ignition OFF.
• If verifying pressure, connect the fuel pressure gauge with Ford adapter to the fuel rail service point if equipped and confirm pressure is relieved.

Step 2: Disconnect the battery

• Use a 10mm socket and ratchet 3/8-inch drive to loosen the negative battery cable clamp.
• Remove the negative cable from the battery post and position it so it cannot spring back.
• When reinstalling later, tighten the battery terminal snugly by hand with the ratchet. If using a torque wrench, Torque to 5 Nm (44 in-lbs).

Step 3: Raise and support your Fusion

• Use the floor jack rated 3-ton minimum at the approved rear jacking point.
• Raise the rear of the vehicle high enough to access the fuel tank.
• Place jack stands rated 3-ton minimum under the approved rear support points.
• Lower the vehicle gently onto the jack stands.
• Keep the floor jack rated 3-ton minimum nearby as backup support.
• Never work under only a jack.

Step 4: Remove underbody panels near the tank

• Use the 8mm socket, ratchet 3/8-inch drive, and extension 3/8-inch drive 6-inch to remove any plastic shield fasteners around the tank area.
• Use the trim clip removal tool for push-pin retainers.
• Set the panels and fasteners aside in order.
• Reinstall shield fasteners later snugly; typical small shield fasteners tighten to Torque to 3-5 Nm (27-44 in-lbs).

Step 5: Support the fuel tank

• Place the transmission jack under the center of the fuel tank.
• Put the wood block 12-inch between the jack pad and tank to spread the load.
• Raise the jack just enough to support the tank. Do not lift the vehicle.

Step 6: Disconnect fuel filler and vapor connections

• Use the flathead screwdriver 1/4-inch to loosen hose clamps if equipped.
• Use the fuel line disconnect tool set to release quick-connect vapor or fuel fittings.
• Place the fuel-safe drain pan 2-gallon below the fittings before disconnecting them.
• Use shop towels to catch small fuel drips.
• Mark hose positions with the marker pen so they return to the same locations.
• Do not pry hard on plastic EVAP fittings; they can crack easily.

Step 7: Disconnect the fuel pump electrical connector

• Reach above the tank and locate the fuel pump module wiring connector.
• Press the connector lock by hand and unplug it.
• If the connector tab is dirty, clean it with shop towels before pressing the lock.
• Do not pull on the wires.

Step 8: Remove the fuel tank straps

• Confirm the tank is supported by the transmission jack.
• Use a 13mm socket, ratchet 3/8-inch drive, and extension 3/8-inch drive 6-inch to remove the fuel tank strap bolts.
• Lower the straps away from the tank.
• When reinstalling later, tighten the tank strap bolts evenly. Typical strap bolt torque is Torque to 35-45 Nm (26-33 ft-lbs).

Step 9: Lower the fuel tank carefully

• Use the transmission jack to lower the tank slowly a few inches.
• Stop and check for any remaining hoses, wiring, or clips still attached.
• Disconnect any remaining quick-connect fittings with the fuel line disconnect tool set.
• Lower the tank fully and slide it out from under your Fusion.
• Slow lowering prevents broken connectors.

Step 10: Clean around the fuel pump module

• Use gasoline-safe cleaner and shop towels to clean dirt from the top of the tank.
• Keep dirt out of the open tank. Even small debris can damage the new fuel pump.
• Use the marker pen to mark the pump module position on the tank before removal.

Step 11: Remove the fuel pump lock ring

• Place the brass drift punch against a lock ring tab.
• Tap the punch with the non-sparking hammer to rotate the lock ring counterclockwise.
• Remove the lock ring and set it aside if it is being reused only for comparison.
• No torque spec applies to removal; the lock ring is a mechanical twist-lock retainer.

Step 12: Remove the old fuel pump module

• Lift the old fuel pump module assembly straight up by hand.
• Tilt it slightly to clear the fuel level float arm.
• Let excess fuel drain into the tank before moving it away.
• Remove the old fuel pump tank seal O-ring by hand.
• Place the old pump into the fuel-safe drain pan 2-gallon.

Step 13: Install the new seal and fuel pump module

• Wipe the tank opening with shop towels.
• Install the new fuel pump tank seal O-ring onto the tank opening by hand.
• Lower the new fuel pump module assembly into the tank carefully.
• Keep the fuel level float arm from bending or catching on the tank opening.
• Align the new pump module with the marks made earlier using the marker pen.

Step 14: Install the new lock ring

• Place the new fuel pump lock ring over the pump module.
• Use the brass drift punch and non-sparking hammer to turn the lock ring clockwise until fully seated against its stops.
• No numeric torque spec applies; the lock ring must be fully seated and locked under all retaining tabs.

Step 15: Raise the fuel tank back into position

• Place the tank on the transmission jack with the wood block 12-inch supporting it evenly.
• Raise the tank slowly under your Fusion.
• Reconnect the fuel pump electrical connector by hand before the tank gets too close to the body.
• Reconnect fuel, filler, and vapor fittings by hand until each one clicks.
• Use the fuel line disconnect tool set only if a connector needs to be repositioned.

Step 16: Reinstall the fuel tank straps

• Lift the tank fully into place with the transmission jack.
• Position the tank straps by hand.
• Install the strap bolts using the 13mm socket, ratchet 3/8-inch drive, and extension 3/8-inch drive 6-inch.
• Use the torque wrench 3/8-inch drive foot-pound to tighten the strap bolts evenly to Torque to 35-45 Nm (26-33 ft-lbs).

Step 17: Reinstall underbody panels

• Position the shields by hand.
• Install push clips by hand.
• Use the 8mm socket, ratchet 3/8-inch drive, and extension 3/8-inch drive 6-inch to reinstall screws.
• Use the torque wrench 3/8-inch drive inch-pound to tighten small shield fasteners to Torque to 3-5 Nm (27-44 in-lbs).

Step 18: Lower your Fusion and reconnect the battery

• Use the floor jack rated 3-ton minimum to raise the vehicle slightly off the jack stands.
• Remove the jack stands rated 3-ton minimum.
• Lower the vehicle to the ground slowly.
• Use the 10mm socket and ratchet 3/8-inch drive to reconnect the negative battery cable.
• Use the torque wrench 3/8-inch drive inch-pound to tighten the terminal to Torque to 5 Nm (44 in-lbs).

Step 19: Prime the fuel system

• Reinstall the fuel pump fuse or relay by hand.
• Turn the ignition ON for 5 seconds without starting the engine.
• Turn the ignition OFF for 10 seconds.
• Repeat this ON/OFF cycle 3 times to fill the new pump and fuel lines.
• Check under the vehicle for leaks before starting.

Step 20: Start the engine and inspect for leaks

• Start the engine and let it idle.
• Use safety glasses and inspect under the vehicle for fuel drips or fuel smell.
• If you see or smell fuel, shut the engine off immediately and recheck the fittings.
• Do not drive until all leaks are fixed.

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✅ After Repair

• Confirm the engine starts normally after sitting for 10-15 minutes.
• Check the fuel gauge for normal operation.
• Road test your Fusion for 5-10 minutes, then inspect again for fuel leaks.
• If the check engine light comes on, scan for codes before continuing to drive.
• No battery registration, coding, or infotainment reset is required for this repair.

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💰 DIY vs Shop Cost

Shop Cost: $850-$1,400 (parts + labor)

DIY Cost: $250-$550 (parts only)

You Save: $600-$850 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 3.5-5.0 hours.

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🎯 Ready to get started?

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