Mk6 2.3 Petrol/LPG Fuel Pump Replacement

[dieselhead123]

Recently a repair to a forum member's vehicle, (Mk6 2.3 Petrol LPG van), necessitated the replacement of the electric fuel pump installed within the fuel tank. As the owner found out, Ford only sell the complete tank assembly which includes the fuel sender, the plastic housing and a length of wiring loom Worse still, no pattern parts are available and Fords retail price including VAT is a whopping £560
We removed the 'pump assembly' from the member's van and returned to the workshop to consider the options.

Something I found during my time with a vehicle manufacturer was that manufacturers buy most of their parts in, this can be small items such as nuts/bolts, ranging up to body glass, large plastic moldings and even engine/transmission units. So the search for an electric pump supplier began

We managed to track down a pump supplier willing to sell us one as a 'sample' and had it sent to us on an overnight courier. If any of you need one, let me know and we can have one sent directly to you.

Here you can see a series of pictures taken during disassembly that will enable you to fit the replacement pump into your pump housing.

The pump and housing should look like this;


Start by removing the wiring connection from the pump, a small flat bladed screwdriver can be used to release the terminal 'clip';


There are two screws holding the base part of the housing in place, these have a 5mm hex head;


The second also secures the fuel tank sender and the earth connection for this, DO NOT forget to re-connect this wire when you re-assemble;


The base housing can then be removed;


The pump can then be withdrawn from the base of the housing, you will need to cut off the hose 'crimp' that secures the supply hose to the pump, a new clip will be supplied with the replacement pump;


You pump and strainer assembly should look like this;


You now need to remove the strainer from the base of the pump, carefully prise this off taking care not to damage the connecting 'clip';


Your old pump will now look like this;


Now remove the rubber 'isolator' from the top of the pump;


Your pump will now look like this;


Now remove the rubber 'isolator' from the bottom of the pump;


You have now completed the removal, reverse the process to re-assemble the pump housing.

You can now re-fit the housing to your tank.

Hope this helps you chaps save a few pounds, let me know if you need one and we will arrange shipment.

TIM

[Rowdey]

And the forum member was very grateful Indeed..!
Top man, cheers

[hollingtontranny122]

Nice one lads that's well handy to know
It can be done with out getting chained
By ford when the time comes! and having the
Easy to follow pics up here to help

[mealic]

Well done Tim!!

Good job mate.Welcome to the wonderful world of the Mk6 petrol LPG.

Hope you didn`t mind me suggesting your skills to Dave

[Rowdey]

He's good but not crazy... He's sending Adam up next time...!

[josmatt]

hi can these pumps still be bought.thanks

[madmart132]

Hi Josmatt welcome to the forum the pump is I believe the same as the mk 5 smiley face transit and several other ford cars one of my vans did 20k with the pump from a sierra in the tank !!
Look on eBay or phone Tim he will sort you out

[josmatt]

hi do you mean the 2.0l petrol ,thanks for your reply

[dieselhead123]

Hi there, sorry for the late reply to your posts, been away a few days

I an certain we can still supply them, just PM me the postage address and I will confirm things in the morning for you.

TIM

[fzrtdizxr]

hi
just bought a mk 6 2002 2.3 petrol/lpg lwb hi top and the next day the fuel pump goes (or so the breakdown mechanic said) there still over £500 from ford
can you still get the pump would be much appreciated
cheere
steve

[madmart132]

I would be a bit suspicious of anything a breakdown mechanic says to be honest , I would check fuse and relay first .
But if it is the petrol pump I would look on ebay , you will have to remove the petrol tank , on the top of the tank will be a round plastic lid with wires going into it . Remove the lid etc rest is on the photos Dieselhead posted . Then measure the hight of petrol pump and order a generic pump from ebay they are almost identical to various other ford pumps and will fit multiple applications and are pretty easy to fit to be honest

[flashbaztard]

hi hope somebody reads this but i have no fuel coming through! anybody tell me which fuse and relay it is before i check the pump! [suppose i could check if power getting to pump!]

[dieselhead123]

If I remember I will look it up for you tomorrow and post up the info. Is yours the early analog cluster or the later digi one? There are some differences in wiring between the two although fuses and relays might be the same.

If you want to check your pump is working, place your hand under the bottom of the tank and get an assistant to turn on the ignition. You should hear/feel the pump operate for a few seconds. The pump is PCM contrulled so does not operate all the time, best way to test is to access the pump wiring and supply a 12volt live and earth, forcing the pump to run. If you don't hear it run then it's stuffed.

TIM

[flashbaztard]

thank you will test in morning

[johnniieee]

Hi I would like a fuel pump if you can get on in for me
How much are they ?
Mk6 2006 bi fuel petrol/lpg
low roof
cheers
johnniieee