Ford Focus Service Manual: Fuel Tank Filler Pipe

Fuel Storage Tanker 164-R3202 or equivalent

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: Remove
the fuel filler cap slowly. The fuel system may be under pressure. If the fuel filler cap is venting vapor or if you hear a hissing sound, wait until it stops before completely removing the fuel filler cap. Otherwise, fuel may spray out. 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: 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. Disconnect the battery ground cable. For additional information, refer to Section  414-01.

1. Carefully turn the fuel tank filler cap counterclockwise approximately one-fourth turn until the thread disengages and position aside.

1. Insert a suitable drain tube into the fuel tank filler pipe until it enters the fuel tank inlet, opening the safety valve.

1. Attach the Fuel Storage Tanker to the fuel drain tube and remove any residual fuel in the fuel tank filler pipe.

1. Remove the RH rear wheel and tire. For additional information, refer to Section  204-04.

1. Remove the retainers and the RH rear splash shield.

1. NOTE:

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

   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 fresh air hose from the Evaporative Emission (EVAP) canister.

1. Disconnect the fresh air hose fitting from the fuel tank filler pipe housing.

1. Remove the 2 bolts from the fuel tank filler pipe brackets.
   • To install, tighten to 11 Nm (97 lb-in).

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

1. Remove the fuel tank filler pipe.

1. To install, reverse the removal procedure.