Tuesday, April 5, 2011

how to replace fuel pump on 2001ford focus wagon

Intermittent pump failure can lead to poor engine performance, stalling and no-start conditions. If the pump cannot bring gasoline up from the fuel tank and send it forward to the fuel injectors at a constant rate, the entire Focus will be rendered useless.

  • Start the Focus, remove the fuel system fuse and wait for the car to stall out. Turn the key off, replace the fuse and then disconnect the negative battery cable with the battery wrench. The fuse panel is under the dashboard and the fuse location is listed in the specific car's owner's manual.

  • Lift the rear end of the Focus so you can position the jack stands under the rear frame. Set the Focus down on the jack stands. Make sure the stands are not placed in a manner that will interfere with removing the gas tank.

  • Move the floor jack under the gas tank and raise the jack head up until it rests squarely against the bottom of the tank. Remove the gas tank retaining strap bolts with the socket set.

  • Lower the tank slowly with the floor jack. Bring it down far enough to allow you to disconnect the fuel filler neck, fuel lines and wiring harness from the top of the tank. You will need the socket set to accomplish this.

  • Lower the tank the rest of the way down and pull it out from under the Focus.

  • Wrap a rag around the end of the screwdriver's tip and place the tip on the vertical edge of the fuel pump retaining ring. Tap the handle of the screwdriver with the rubber mallet until the retaining ring rotates and releases the fuel pump.

  • Lift the fuel pump out of the tank by hand and set it aside. Remove the old fuel pump gasket, put the new one in its place and lower the replacement fuel pump into the tank, facing the same direction as the old pump. Make sure you do not bend or otherwise deform the fuel level float arm during the installation. It is also best to make sure the fuel level float arm has proper clearance inside the tank, so that it will not hit the tank walls during normal operation.

  • Reinstall the retaining ring, fuel tank, fuel lines, fuel filler neck and fuel pump wiring harness in reverse of how you removed them. Reconnect the negative battery cable.

  • Turn the ignition key to the run position and let it sit for ten seconds before turning it back to "OFF." Repeat this step twice more and then start the Focus. Get out and look for any leaks on or around the fuel pump, lines and filler neck before lowering the Focus off the jack stands.

    ------------------

    The installation procedure:-----

    Preparation

    • Siphon off as much fuel as possible if you can't wait until the fuel tank is nearly empty from running the car; use a vacuum pump or other siphon tool and deposit the fuel into a gas can.

    • Open the filler cap at the side of the car and remove the number 12 fuse from the fuse box. Start the car and wait for it to stall out, depressurizing the fuel system.

    • Raise the rear end of the car, support it on jack or axle stands and block the front wheels with wheel chocks. Remove both rear wheels.

    Tank/Pump Removal

    • Detach the exhaust flange at the exhaust system's front by removing the nuts behind the flexible pipe. Remove the exhaust heat shield by removing its flat nut fasteners with a flare nut wrench and unhooking the mounting rubbers at the front and rear ends of the exhaust system (this requires a special tool).

    • Move the disconnected exhaust system underneath the car so it is clear of the fuel tank. Support the system's front end with another axle stand and support the rear end with the car's rear suspension cross-member.

    • Disconnect the filler pipe and vent hose from the tank; loosen their clamps with a screwdriver or pliers. Disconnect the charcoal canister by pulling off its vapor hoses, releasing the fitting at the hose, pressing the metal clip and lifting the canister upwards.

    • Disconnect the fuel lines from the fuel filter; pry out the insert to release the fittings.

    • Raise a floor jack with a block of wood under the tank, unbolt the tank strap with a wrench and a socket extension, unhook the straps and lower the tank with the jack.

    • Disconnect the fuel lines from the fuel pump module; use a small screwdriver to release the lines' fitting lugs. Note that the fuel supply line connector has a white band while the return line connector has a red band.

    • Unscrew and remove the module's retaining ring. You can use an oil filter strap wrench or large slip joint pliers, but a special Ford-issued service tool (310-069) is recommended.

    • Withdraw the top cover for the current pump and sender unit and feed its wiring out through the hole. Turn the pump and sender unit counterclockwise and withdraw the unit from the fuel tank. Remove the rubber seal on the pump's periphery.

    Tank/Pump Installation

    • Insert the fuel pump into the fuel tank. Make sure the pump is fully seated within the tank then turn it clockwise to secure it in the tank.

    • Connect the top cover for the pump and turn it so the arrows on the pump unit and the fuel tank line up. Install a new rubber seal on the fuel pump, then install and tighten the retaining ring with the same tool you removed it with.

    • Reconnect the fuel lines to the tank and lift it back into position on the car using the jack. Hook the straps back into place and secure them with the strap bolt.

    • Reconnect the fuel lines to the fuel filter, using the same red/white bands as a guide for the fuel pump connections. Reinstall the charcoal canister and reconnect the fuel filler pipe and vent hose to the tank with their clamps.

    • Maneuver the exhaust system back into place and connect the mounting rubbers, the heat shield and the exhaust flange.

    • Reconnect the rear wheels and lower the car. Pour the fuel back into the tank through the filler pipe on the side and reconnect the battery cable and the fuel pump fuse.

    • Turn the ignition key to the "On" position for about 10 seconds, turn it off and repeat twice more to repressurize the fuel system.

  • max