🔧 Fusion - Fuel Pump Module Replacement

The fuel pump on your Fusion is part of a module beneath the rear seat cushion. Replacement involves relieving fuel pressure, opening the service cover, disconnecting the fuel line and installing the new module with a fresh seal.

Difficulty Level: Intermediate | Estimated Time: 2-3 hours

Assumption: These instructions cover the original in-tank pump module and factory fuel system.

---

⚠️ Safety & Precautions

• 🔥 Work outdoors or in a well-ventilated area, away from flames, heaters, cigarettes and tools that create sparks.
• 🧯 Keep an ABC-rated fire extinguisher within immediate reach.
• ⚡ Disconnect the negative battery cable after relieving fuel pressure.
• 🛡️ Wear safety glasses and fuel-resistant gloves. Gasoline can injure your eyes and skin.
• ⛽ Reduce the fuel level below one-quarter tank before starting.
• 🚫 Never test the pump by applying battery power directly to its terminals.
• 🧹 Clean around the module before opening the tank. Dirt entering the tank can damage the new pump.
• ♻️ Collect spilled gasoline in an approved fuel container and follow Panipat disposal regulations.

---

🔧 Required Tools

You'll need the following tools for this repair:

• 10mm socket
• 1/4-inch drive ratchet
• 1/2-inch drive torque wrench rated 20-150 Nm
• Fuel pump lock-ring tool 310-123 or equivalent (specialty)
• 1/2-inch drive breaker bar
• Plastic trim-removal tool set
• Small nylon cleaning brush
• Fuel-resistant drain pan
• Approved gasoline container
• Fuel-resistant shop towels
• Fuel-resistant nitrile gloves
• Safety glasses
• ABC-rated fire extinguisher

---

🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Complete in-tank fuel pump and sender module - Qty: 1
• Fuel pump module sealing ring - Qty: 1
• Fuel pump module lock ring - Qty: 1
• Fuel-resistant service-cover butyl seal - Qty: 1

---

📋 Before You Begin

• 🚗 Park your Fusion outside on level ground, select Park and apply the parking brake.
• ⛽ Run or safely drain the tank until it is below one-quarter full.
• 🔥 Switch off every possible ignition source and place the fire extinguisher nearby.
• 🪟 Open the doors for ventilation before exposing the fuel tank service opening.
• 📦 Remove belongings from the rear seat and floor area.

---

🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Relieve Fuel-System Pressure

• Use the plastic trim-removal tool to release and lift the front edge of the rear seat cushion.
• Raise the cushion enough to reach the electrical connector at the fuel pump service area.
• Press the locking tab by hand and unplug the fuel pump module electrical connector.
• Start the engine and let it run until it stalls from lack of fuel.
• Turn the key to START for approximately five seconds, then switch the ignition completely off.
• Place fuel-resistant shop towels around the work area because a small amount of pressure may remain.

Step 2: Disconnect the Battery

• Open the hood and use the 10mm socket with the 1/4-inch drive ratchet to loosen the negative battery-terminal clamp.
• Remove the negative cable and position it where it cannot spring back onto the terminal.
• Do not reconnect the battery while the fuel tank is open.

Step 3: Remove the Rear Seat Cushion

• Use both hands to lift the front of the cushion from its retaining clips.
• Push the cushion slightly rearward, then lift it out through a rear door.
• Use the plastic trim-removal tool if a clip remains engaged. Do not pry against painted metal.
• Take a photo of the cushion alignment first.

Step 4: Open the Fuel-Pump Service Area

• Use the plastic trim-removal tool to lift the service cover without bending it.
• Remove the old cover seal carefully and keep loose adhesive away from the tank opening.
• Use the small nylon cleaning brush and fuel-resistant shop towels to remove dust from the module, lines and surrounding tank surface.
• Do not use a household vacuum because gasoline vapor can ignite inside its electric motor.

Step 5: Disconnect the Pump Module

• Confirm that the electrical connector is unplugged.
• Place the fuel-resistant drain pan and shop towels beside the module.
• Push the fuel-line connector slightly toward the module by hand, press its release tabs, then pull it straight off.
• Do not pry the connector or pull on the plastic fuel line.
• Capture the small amount of released fuel in the fuel-resistant drain pan.

Step 6: Remove the Lock Ring

• Fit the fuel pump lock-ring tool 310-123 or equivalent squarely onto the lock ring.
• Use the 1/2-inch drive breaker bar to rotate the ring counterclockwise.
• Do not use a steel hammer and punch. A spark near gasoline vapor can start a fire.
• Lift off the lock ring and set it away from the clean tank opening.

Step 7: Remove the Fuel Pump Module

• Lift the module slowly by hand while allowing fuel inside it to drain back into the tank.
• Tilt the module only as needed to clear the fuel-level float arm without bending it.
• Place the removed module upright in the approved gasoline container.
• Remove and discard the old sealing ring from the tank opening.
• Use fuel-resistant shop towels to wipe the sealing surface. Do not allow debris to fall into the tank.

Step 8: Install the New Pump Module

• Place the new fuel pump module sealing ring into its groove on the tank.
• Lower the new module into the tank by hand, guiding the float arm through the opening.
• Align the module locating marks with the marks molded into the fuel tank.
• Verify that the sealing ring remains flat and is not pinched beneath the module flange.

Step 9: Secure the Pump Module

• Install the new lock ring by hand and start it evenly in the tank retainers.
• Fit the fuel pump lock-ring tool to the ring.
• Use the 1/2-inch drive torque wrench to tighten the lock ring to 81 Nm (60 ft-lbs).
• Stop if the module turns out of alignment or the sealing ring begins to squeeze outward.

Step 10: Reconnect the Fuel Line and Wiring

• Push the fuel-line connector onto the new module by hand until it clicks.
• Pull gently on the connector by hand to verify that it is locked.
• Push the electrical connector into the module until its locking tab clicks.
• Use fuel-resistant shop towels to dry the area completely before reconnecting the battery.

Step 11: Prime and Inspect the Fuel System

• Use the 10mm socket and 1/4-inch drive ratchet to reconnect the negative battery cable.
• Switch the ignition to ON without starting the engine for five seconds, then switch it off for ten seconds.
• Repeat the ON-and-OFF cycle three times to fill and pressurize the new module.
• Inspect the module seal and fuel-line connector visually and by touch for wet gasoline.
• If any fuel appears, switch the ignition off immediately and disconnect the negative battery cable with the 10mm socket.

Step 12: Reinstall the Service Cover and Seat

• After confirming there are no leaks, switch the ignition off.
• Apply the new fuel-resistant service-cover butyl seal around the opening by hand.
• Press the service cover evenly into the seal.
• Place the rear edge of the seat cushion beneath the seatback.
• Align the front retainers, then press firmly downward by hand until both clips lock.
• Pull upward gently at each front corner to confirm the cushion is secure.

---

✅ After Repair

• 🚗 Start the engine. A slightly longer first crank is normal while remaining air clears from the line.
• 👃 Switch the engine off immediately if you smell strong gasoline or see a leak.
• 🔍 Let the engine idle for five minutes and inspect beneath the vehicle and around the service cover.
• ⛽ Verify that the dashboard fuel gauge responds correctly. It may take several minutes to stabilize.
• 🛣️ Take a short local test drive, then recheck for fuel odor or leakage.
• ⚠️ If the engine does not start after priming, do not repeatedly crank it. Recheck the electrical connector, fuel-line engagement and module compatibility.

---

💰 DIY vs Shop Cost

Shop Cost: ₹18,000-₹35,000 (parts + labor)

DIY Cost: ₹9,000-₹22,000 (parts only)

You Save: ₹9,000-₹13,000 by doing it yourself!

Panipat labor rates and imported-part prices vary. This repair takes a shop approximately 1.5-2.5 hours.

---

🎯 Ready to get started?

HowToo makes it easy: same-day/2-day shipping on every part, plus all the tools and specialty tools you need! Check out the parts and tools sections below to add everything to your cart.