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Fuel Tank Filler Pipe > < Fuel Pump Module

Focus 1999 (08.1998-12.2004)

Fuel Tank and Lines - Fuel Tank Focus 1999 (08/1998-12/2004)
Removal and Installation

Removal

WARNING:
WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.
WARNING:
WARNING:This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury.
WARNING:
WARNING:The fuel system remains pressurized for a long time after the ignition is switched off. The fuel pressure must be relieved before attempting any repairs. Failure to follow this instruction may result in personal injury.
  1. Depressurize the fuel system. For additional information, refer to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information / 310-00C Fuel System - General Information.
  1. Drain the fuel tank. For additional information, refer to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information / 310-00C Fuel System - General Information.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Detach the exhaust pipe from the rear hanger insulator.

  1. Detach the exhaust pipe from the hanger insulator.

  1. Detach the center muffler from the hanger insulator.

  1. Disconnect the exhaust pipe.
    1. Remove the nuts.
    1. Detach the exhaust pipe from the two insulators.

  1. Remove the heat shield.

  1. Secure the exhaust pipe in a suitable position.

  1. CAUTION:
    CAUTION:When removing the fuel tank vent and filler pipes, do not use any sharp edge tools to lever off the pipes. Failure to follow this instruction may cause damage to the filler pipes.
    NOTE:
    NOTE:Make note of the positions of the retaining clamps to make sure they are positioned in exactly the same positions when installing.
    Disconnect the fuel tank vent pipe and filler pipe.

  1. Disconnect the fuel tank vapor pipe from the evaporative emission canister.

  1. Disconnect the evaporative emission pipe from the canister.

  1. NOTE:
    NOTE:Use a flat blade to depress the clip.
    Depress the evaporative emission canister retaining clip.

  1. Remove the evaporative emission canister.

  1. Disconnect the in-line fuel couplings. For additional information, refer to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information / 310-00C Fuel System - General Information.

  1. CAUTION:
    CAUTION:When supporting the fuel tank, use a suitable packing material to prevent damage to the underside of the fuel tank.
    Place a suitable high-lift jack under the fuel tank.

  1. Remove the fuel tank support strap bolt.

  1. CAUTION:
    CAUTION:When lowering the fuel tank, make sure that excessive strain is not placed on the fuel lines and electrical connectors.
    Partially lower the fuel tank.

  1. Disconnect the fuel pump electrical connector.
  1. Remove the fuel tank.
  1. If installing a new tank, remove the roll-over valves, filler pipe and vent pipe and install into the new tank.

Installation

CAUTION:
CAUTION:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow this instructions may result in personal injury.
NOTE:
NOTE:When installing the fuel tank make sure the fuel lines do not get kinked or trapped.
  1. NOTE:
    NOTE:The fuel filler and vent pipe retaining clamps must be installed in the same position as removed.
    To install, reverse the removal procedure.

  1. Initialize the door window motors. For additional information, refer to Section  501-11 Glass, Frames and Mechanisms.

Fuel Tank Filler Pipe > < Fuel Pump Module