Ford Focus Service Manual: Fuel Tank and Lines - Removal and Installation

Removal and Installation

WARNING: Do not
smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Do not
carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: When handling
fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.

WARNING: Before
working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

WARNING: Always
disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section  100-02.

1. Release the fuel system pressure. For additional information, refer to Section  310-00.

1. Disconnect the battery ground cable. For additional information, refer to Section  414-01.

1. Drain the fuel tank. For additional information, refer to Section  310-00.

1. NOTE:

   Clean the Fuel Pump (FP) module connections, couplings, flange surface and the immediate surrounding area of any dirt or foreign material.

   Disconnect the FP module electrical connector.

1. Remove the 2 nuts and position the fuel tank heat shield aside.

1. NOTE:

   Index-mark the fuel tank filler pipe hose clamp for correct installation.

   NOTE:

   Some residual fuel may remain in the fuel tank filler pipe after draining the fuel tank. Carefully drain any remaining fuel into a suitable container.

   Release the clamp and remove the fuel tank filler pipe hose from the fuel tank.
   • To install, tighten to 4 Nm (35 lb-in).

1. Disconnect the fuel vapor tube assembly-to-fuel tank quick connect coupling. For additional information, refer to Section  310-00.

1. Disconnect the fuel supply tube-to-fuel tube quick connect coupling. For additional information, refer to Section  310-00.

1. Install a suitable lifting device under the fuel tank.

1. Remove the bolt and the fuel tank straps.
   • To install, tighten to 25 Nm (18 lb-ft).

1. Partially lower the RH side of the fuel tank, allowing it to clear the heat shield, then lower completely and remove.

1. To install, reverse the removal procedure.