Replacing a Ford Focus Fuel Pump - The Easy Way
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- Опубликовано: 17 фев 2013
- Follow this procedure at your own risk! Making sparks directly over the fuel tank and blind to where the fuel lines are is obviously risky. I survived, but will you?
2002 Focus had no fuel pressure. Previous owner described difficult starts for a couple months tapering into a no start. Learn how to make your fuel pump replacement procedure easier now and in the future. 
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i have done this in 4 cars and a truck. with a chisel and hammer. metal is very soft and one wack with hammer you get a half inch. it doesnt take but 2 minutes!and u can use a wood chisel just fine. its real easy trust me. i have done on side of interstate and got the car fixed in 15 minutes! one tip: cut 3 sides only and when done just fold it back over. i then take light sheet aluminum and place over it, slide carpet over it or tape it and viola . maybe put a few screws in it but hey, its going to the scrapper someday anyway.
Yes it works. £300 from a garage to do the job and 3 days wait. They advised me to go in through the top as this guy did. I used tin shears! Not and angle grinder! Cut from the hole out and peel back enough metal to acces the pump top ring. remove pump and replace with a new one £90 from the shop that advised me (only fair to order from them!). 280mm x250mm sheet steel with a 50 hole in it. Cover the access using silicon and sheet metal screws. Spray with primer. Use sound insulation. refit back seats. 4hours work including silicon and paint drying time. Job done :-) No need for a split the 50mm hole means you can fit the connector through and use the original rubber bung.
Thanks to your video I just got my pump out, I uses some metal cutting hand snips instead as I was nervous of sparks and cutting cables but cut through like butter and was out in about 10 mins, cheers for the information!!
What snip tool did you use, may i ask?
I used wire cutters and after drilling a few, lol holes, in the shape of a sort of circle. LMFAO!
Nice job, Alex. You are a very resourceful young man and very clever. I was able to cut through the floor above the gas tank on my car with a good pair of sheet metal sheers and access the pump. Also, thanks to you, I was very careful and did not damage the vent tube. Kudos to you for this video and keep up the good work!!!
Your not being serious right?
Just finished mine. Cut hole with tin snips. Lucky to get a NEW pump for $ 60.00. Bent the floor metal back into place. Used AC duct tape with the sealer on it to cover, then screwed on some sheet metal. Thanks again. Now with the gauge working, can get state inspection.
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Hello there,
I cut an access hole last weekend and did my pump replacement, was apprehensive at first but I took my time and everything worked out well and I saved a heap of money. i sealed the hole with some undercoat material and the ol girl drives as good as new. Thanks for the video.
the only failure is not trying !
very good intuitive video saved me at least £100 in labour cost, i did this on my 3dr hatch back i used a dremel 8200 multi tool, cut a neat square just larger than the pump, just one suggestion to add - i removed the petrol cap before i disconnected the 2 fuel pipes located on top of the pump as i found the pressure was pushing the fuel out the top. took me a cautious 2hours start to finish but next time 30mins id reckon, thanks again
The tank is no less than an inch away from the metal panel you would be cutting at any point. It doesn't take a large amount of skill to keep the blade within an inch tolerance. If you were worried, you could use a Dremel at the expense of spending a little more time cutting. If you don't feel comfortable doing this then it's your choice. I simply provided instructions for an alternate solution. As with any instructions, use at your own risk, and you have the right to not follow them.
Brother you did a really good job oh, I've had situations like this where work was Far easier to cut in through the top seat. However I do suggest using an oscillating tool instead of that grinder. Because unlike a cigarette one of those Sparks could blow that thing up. The oscillating tool is slow enough it does not Produce Sparks at all and it's more efficient to move along.
Thanks Alex. Changed my pump out and it cost me about $70.00. $50.00 for the ac delco and another $20.00 for sealant and self tapping screws. used thick guage sheet metal instead of a doner plate and extra silver tape and dynomat I had laying around to finish it off. If I ever have to do it again it will be a breeze. Appreciate your video.
Yes, this indeed works, my son-in-law and I just replaced his fuel pump from inside the back seat area. The new pump was made somewhat differently and so we had to remove the original equipment plastic mounting ring from inside the tank. I bled a bit. However, all things considered, the job too far less time than if we had taken out the tank along with all the trimmings. Thanks!
Super easy. As long as you stop hen you feel like you're through the metal, you're good. I suggest not cutting a whole square of metal out. Let it hinge from the part of the metal that is the lowest part of the slope. Or the back cushions of the seat if that makes sense. You're more likely to nick the wires coming through that area. You can also pop the rubber grommet that protects the pump wires through the top of the metal from the bottom then use a tin snip to cut a slot for those wires to slide out of.
Alex,thanks for posting! Pay no mind to rude comments my friend! Be nice people... He is trying to help us.
You are REALLY A MECHANIC like in the movie...you blown out all away...I have never seen repairs like this before.
Y do u look like Cameron from Ferris Bueller's day off? Lol but thanks for sharing dude
you could have used the entire replacement assembly because it was the updated version. No need to take pump out and put in old holder. You would then use the pressure hose from the newer assembly to connect to filter.
Exactly! There was far too much effort put into what should’ve otherwise been a simple removal/install.
Oh and having read most of the comment below about its easier just to drop the tank! It isnt on a 15year old car! the bolts WILL shear and the straps will break. Most modern manufacturers have an access panel above the fuel pump so this is a viable alternative. Ok not Ford recommended procedure but they had a design flaw in the first place by not allowing access from the top! :-)
Great video, I was going to put one up of this job myself but then I found yours !! It would be a waste of my time to do a video on this job, as this is perfectly explained. Experienced technician from England saying thumbs up !!!!!
Glad I was able to help you. If you didn't already, make sure you take time to rustproof the exposed metal and do your best to seal the floor up. You don't want moisture or especially exhaust fumes coming into the passenger compartment.
#1, good method if you don't have a lift. good work youngster. I got lifts so, don't ever cut on a car for access. but I can drop the tank and change the pump in around 15 mins as long as it isn't rusty. just did one today. I don't completely remove the tank but drop just enough to change the pump.
Exactly what my 2002 ford focus needs in time for fall semester. Ill be showing my brother this video so he can fix it in no time! Extremely helpful! And handsome too!
used this idea today cutting a hole good time saver not for the beginner but someone with the skills easy peasy,looked at taking the tank out but it would have opened a can of worms and resealed with tech 7 adhesive very good sealant I use on boats superb!! remember to reinsulate the wires well done alex lateral thinking Nice!
The car you got the pump out of is 2006-07 which has a higher flowing more durable pump that is pulse width modulated. Ford Changed the shape of the connectors on them for the different engine it is used on which is why none of them interchanged.
Awesome video. Thank you so much for this. Anytime I'm looking for a how to video its always some grainy fuzzy useless tutorial with a guy you can't understand at all talking about everything but how to do what you need to learn for 80% of the video. I'm going to look at an 01 ZX3 this weekend and I've red this is a common problem. I feel a lot more comfortable with dealing with a bad fuel pump after watching your video. I'm pretty nervous about all that wiring and hoses you almost cut through but maybe if this happens to me I'll use. Dremel and carefully cut the sections where there's wiring. Thanks again man this was a top notch tutorial.
Thanks so much for the helpful video! Saved me a bundle. I used your process, including using an angle grinder for cutting out the access opening for the fuel pump. Worked great for me! The only safety criticisms I have are... 1) having a fuel pump with fuel in it near an electrical power supply that has the potential to spark when connected; 2) I wasn't a fan of starting the car with fuel vapors potentially in the air in the garage, less air movement, and potentially a stray spark from bad plug wires. Yeah, it would have been extra work to get a dead-in-the-water vehicle outside to test-fire start it up. The irony is that the original problem was actual a bad inertia switch, in the passenger side kick panel, which made it *seem* like a bad fuel pump problem. Also thank you for showing the process to bench-test the fuel pumps, and the difference between fuel pump styles.
Pls what is inertia switch pls
Droping the tank works faster and you dont have to get blown up!!! Not smart!!!
Alex you did a job well done I am not trying to take away from that except to give you props for doing it.
thank you very much a video was very very helpful I'm facing the same issue although I did upon purchase of the vehicle had a used fuel pump from the junkyard put in three months ago about two thousand miles or so fuel pump is not working although I will check the fuel filter first car runs on starting fluid only for a few moments at this point Thank you again
wheather people like it or not( i didnt like the way you did it, and i think you been lucky) it is one way to fix problem, job done! thats counts! about insurance claim, they wont even check this junk car( i have one exaclly same model) it wont worth much anyway as long as you didnt get hurt! i'll give you thumbs up. You tryed , you fixed it and good presentation 👍
Man u r a genius today i changed my fuel pump as u have discribed thanks man
It just happend to me today will try that way as dont have any lifts hope will not burn my self and dont blow up my car with me inside thanks for this post very helpful
WOW.... me too,,, what is going on ?????
I think there is something in the air
As I said earlier, the two pumps I had were different. Whether they were interchangeable or not, I don't know. I was told they were but I was unable to make it happen. As you can see in this video, I simply removed the actual pump motor and modified the plug so that it could be used. I have had no issues with this setup.
Good job Alex! Nice series now time for the tractors!
I have never seen repairs like this before. It worked but you cut your car up.
This is very common and easy fix i did the same on my 94 camaro cause u have to drop the whole rear end to get the tank down but u may not need that in focus
Just wanted to Thank you for a fantastic idea. Saved me loads of time. Ford should have bolted an access panel there if they were thinking! Again , thanks so much! Your tops in my book! Take care and God Bless! :-)
this is great thanks for the video made things easyer
That's why you don't buy junk yard parts, and you're dry firing it😖 your a real life Tim Taylor!!! Taking out the back seat and cutting the floor open isn't quicker than unbolting two straps.
Haha "Why would you do this to me Ford?" So true!
Makes me glad to own the 2012 VW Jetta I do. Fuel pump is 30 min going by the official way, 45 min or so for the heater core etc. Only thing that stinks on my car is the radiator. Not looking forward to this iob on my wife's car. Thanks for the tips to make this easier!
nice man , i dont need to change my pump but i learned from you , thanks
2010 focus SEL. Make sure when you reinstalll the fuel pump that the black circular retaining ring is the correct orientation. It is counter intuitive to what it looks. I was fighting it for quite sometime before I figured it out. Also my fuel connection was different. It was red and black but connected differently. On mine you had to pop a red tab then pull it perpendicular with pliers. Kind of like a linch pin.
ok , I have replaced quite a few and taken the type out that you had and the new ford OEM replacement was like that you got from the junk yard, but very good video non the less, good job. very creative. For work I always have to take the tank down but I have done your method a few times on a few different cars. I do it different but the result is the same. and at least you are doing it..
Excellent video so easy to follow
My replacement assembly (fuel line broke when removing it) was like the the donor one. You have to press it into place and hold when you twist on the lid. The spring "locks" in the assembly and keeps it from moving... No quarter turn "lock into place".
I hear that it's a fairly straightforward swap. If you have the means and the motivation it's probably the way to go. I just wanted a cheap reliable fix, I'm not worried about performance. It's just a Focus, after all.
This video is actually very helpful.
Makes sense to do sometimes but this is a pretty easy job without cutting out the floor.... can be done in an hour if you have done it before
Done it "the hard way", dropped a tank, and it takes few minutes longer due to rusted clamp on a filler hose that I had to cut(awkward angle and very tight space) and you need to have some time to syphon a fuel, only condition is that you need to have a place to get under a car, I cant imagine doing this on a floor when lifting a car with jacks
My dude!!!! You’re the best!
most cars I've worked on, the rear seat hinges up and there is a access hatch for the top of the tank!
where did you get the sealant and the tape that you covered the cap with great video btw
You don't have to. The Ford recommended procedure is to remove the fuel tank from underneath. This is easy at a dealership on a new car, but for the average home mechanic (which is who these videos are made for) it can be very difficult. Bolts will rust and seize causing problems when removing the tank. Also, not everyone has the tools to safely lift and support a car.
TheAlexManVideos so the average home mechanic has a metal saw?
@@mikebeck5492 if you dont have something to cut metal like really what are you doing? Grinder, sawzall, jigsaw, or just drilling a big hole and using tin snips
yea and also if Ford recommends it then it's probably the dumb way todo it! Obviously ford still doesn't know how to make a reliable vehicle even though they have been @ making garbage for this long! Thanks gov for wasting our taxes on bailing out who should be labeled a enemy of the American people! Dumb af! Thanks for the video bro! Very helpful! 💯👍😁
Use a hand or air powered metal cutting tool snips or nibbler (no sparks).
i did the same with my Mondeo Pump.but at the end i used Special Glue to seal the Metall.
Is this common with all fords? I'm helping a friend change out the fuel pump on her ford fusion 08 but have found nothing online so far.
I just saw this done on a 2000 Ford Focus, I actually started searching online for a safer way to do this, then I stumbled upon this video, the mechanic actually went at it using a chisel and hammer, the panel was cut and pump extracted well before I finished watching this.
Question still remains does this car have a problem with the fuel pump? The owner says it loses power intermittently, ideals currently and won't rev on neutral a times. If and when it gains power it would suddenly lose power, won't rev pass 2000 but engine won't cut out.
Any ideas/suggestions?
ok,,,, good to know....
thx for this video. im going to try it.
You just have to move out to East TN to see how it's done out here. I personally got an engine out with my feet kicking it back in the day.. You make do here...
can u please help me ! i have a 2002 ford focus and i see here u have these two similar but different modules. the one without the springs and sort of twist in is the one install in my car but it gave out on me because after a week or two driving because the previous owners had a beat up module assembly but good pump. i purchased a new module assembly and its like the one u got from the junk yard which just sits in the tank unlike the other one. im having a hard time finding one like the other. was there any difference in the car models ? i dnt understand how they can be basically identical except in one area where i have conflict. HELP !?!
It's funny, my land rover discovery actually has an access panel in the cargo area specifically for this purpose. My girlfriends focus will be getting a little trim back there. I'm definitely not dropping the tank. Those fuel hoses are a pain in the ass to disconnect.
nissan sentra 2003 cames with that hole cut out all ready it makes so easy to change the pump
I would think so too but I tried and it would not work. They were different designs and fit into the tank different ways. Not sure why there were two different pumps in two very similar cars.
Well perhaps I was wrong but I tried to install it for a few minutes and I couldn't get the donor pump to install into the tank in my car. Either way, I made it work. Perhaps not the most professional install but I don't think I did anything that would put a future owner in physical or financial harm.
Alex do you still drive your focus and and where is the black box connected to the pum as in my 2000 focus it doest sems to be in the same place as yours
Are you able to access the fuel tank pressure sensor from here? I thought it was on top of the fuel pump but not too sure. I have multiple evap codes. Also, what kind of sealer did you use? Great video!!
Just started the fuel pump video.@ the part where u just got back 2 ur car..y not save ur cars back seat? & drop the tan???.im doing my filter(STARTED IT @ night time, started raining so,1st thing in the morning, I'll fix it & I'm a clean my iac valve (again) mine is a 03 focus L4-vin3 zetec 2.0 Dohc 16v so my intake is on the back side of the motor.making it a pain 2 get 2 the iac valve.i need 2 order 2 new o2 sensors! still runs great even with em being bad tho!!! I'm excited 2 see how good it will run after I get em.sure it'l bake the tires off..199,500- ish miles & it still runs ,Tony the tiger "GREAT"!!!! I'm really surprised a Ford 4 cylinder runs this good especially with it being so old.14yrs old.i have several other plans 4 it.new struts, beating ass system.cab1600.1 amp.hi-amp alternator. 1 fared cap.& 14volt line driver.w/double din wifi head unit..tint, visors, interior neons.etc...
Peeling out the back seat and cutting up the body like that takes way longer than just dropping the tank.........
Mark Reuterskiold youve clearly never done it then. It takes like 45 minutes.
Thank you, I also followed these steps, but I did not cut all the way around, only along 3 sides of a square. The size of the square was 7" x 7", centered on the middle of the hole for the wiring.
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(Sorry for the long pic link.)
Make sure you remove all slag and burrs from the edges of the sheet metal by using a file and/or a knife. Make sure the lid is already on the tank and add a rag, then vacuum all metal particles out before sealing this compartment.
I was curious to see the bad pump motor - please explain to me why it costs $40+.Thank you for the thoughtful design, Ford Motor Company!
I've heard many people say this is easier, not only on Rangers, but other pickups as well.
Hey Alex. Thanks for the video. I plan to buy a new AC Delco pump only (just the pump, w/o the assembly). This should work regardless of which assembly is in the vehicle, right? Also, just curious but why did you use the metal cutout that you took from the donor car to replace the hole you cut in your car?
If you buy the pump only for your year/model/submodel of vehicle it should work just fine. I used the metal cutout from the donor car so I could have some overlap. If I used the original there would be a small gap from the cutting blade. To avoid this I cut the flap in the donor vehicle about 1" wider all around so it could be used as an access door in the future.
the laughs were massive in this video when he broke out the angle grinder.
Thank you for making this video. What did you use to cut the floor, when you were in the salvage yard?
Battery powered angle grinder. Not the smartest thing and most yards won't even allow it.
TheAlexManVideos oh wow! Call me ignorant - I had no idea those battery grinders were useful. My mom’s ZX3 just shut-off one day while warming it up for her errands. Replaced the relay, then finally tracked it to a failed pump. I really don’t want to drop the tank and found you video. Thanks so much, Dude! 👍
Thanks kid you have skills
I totally agree with you, it's a bad design. The cost to engineer a plate with some screws through it can't be very high.
Good Job !!
Hi, I am from venezuela, here we have the ford ecosport and that uses the same motor duratec 2.0 of the focus, great car with great force, I have replacedthe pump previosly but, i have problems with the star engine, I romeved the all pump, and i saw somthing like a check valve after the out line pump, excatly betwen two brown hose, I checked and its so hard to makes the pass of gas, i will have problems if i remove that check valve_? please helpme
True, I would only suggest you do this on your own car.
Next time cut the pumps connection off and swap for the other modules one, very eash to do just like u swapped the motor. The motors adapter should and could have came with it. Test your relay, Test 12v to Inertia from relay, test 12 from Inertia to pump driver, driver to pumps connecter and if 12 ain't there it is not the pump. Also test pump at power prong, sometimes it is the module that got clogged or burnt at the top power wires connection and the pump still works.
I rescued a 2001 from the junkyard. 1st thing I did was bought a battery to crank it over to check for spark, it did crank but I figured out it was not getting fuel. Replace the fuel pump on it ran then the fuel pump went out again because it was a cheap eBay one. Had the fuel pump replaced because I already had the tank out 2 different times before and I was tired of it.Fast forward 2 years later it has been at the shop for 6 months because of a motor issue now that that's fixed the fuel pump says circuit 2 is not receiving information. But yet it runs smoother than a baby's butt it only tries to die once in a while when I am on the highway. Any thoughts on that 1??? I did have a 153 dB subwoofer set up in it though though, maybe that rattled something loose??
you are a smart kid
This guy should not be allowed to do repair video's. First he takes off the head yet it is a fuel pump problem. Wait he did not check pressure. Just luck he was not getting no fuel pressure do to a gas leak. Should have used a non sparking method such as tin snips or ect much posted a warning. Some young kid like him s going to cut through the fuel lines while grinding. He would never be allowed in any real shop. Safety first.
I did the same in my focus. Ford should have designed an access hatch. I didn't go about the same way with the cutting wheel but the end result is the same
dude you would have done it just like any mech would have ,great job showing the rest of the fokes... how to.. aces baby
I did this too (replaced the actual pump only, the rest of the pump mechanism was fine) BUT ever since I have had a LARGE EVAP Leak and I can smell gas in the car. I suspect the leak is in the Lid that holds the pump in. I was careful to mark where the lid tightened prior to removal and tightened it to the exact spot. But man it appears to leak. I am wondering how to ensure that the tank lid is "sealed". And I'm warning everyone to ensure that lid gets sealed or you will get an large EVAP leak (PO455) like I did. The tank doesn't hold the air pressure the Evap system puts in the tank to test the evap system and produces the P0455 (large evap leak) code.
Just cut hole in floor with snips, when I cut and removed floor there was a lot of fuel sitting on top of the pump cover ..what does it mean?
+Matt Kemp
Means good thing you used snips and not a grinder ahhh that would hurt, unless you had a lot of ventilation.Now to be honest I would check your lines or the seal around your pump , one of them is leaking close to the top of the tank unless it is following a line back on the outside of it if you can understand what I am trying to say. Hope this helps you.
i have fordfocus 1.8 diesel 2007. my car is sheking to much when stand. i change injectors as well. somebody tell me what is the fault and what i do.
that was a pretty good the street come on out to do a fuel for placement pump
Hey bro do have same car but on mine after I changed it its not getting fuel down da lines, pump turns on but not sending any fuel
I open pump and hooked up open so I could see wat was going on and I notice dat all da fuel was being sprayed out of that little whole on the plastic piece dat covers the actual small fuel pump( the cover with two screws dat has fuel hose attached to it) when I put my finger on whole to plug it then I get fuel pressure!! I noticed yours didnt have any type of plug on it but why is mine spraying out of there and not urs????
Please learn to write properly so I can understand your problem.
Its only 2 10mm bolts for the band. Would have been less work to drop it. Just gor done with mine
What tools did you use to take out the fuel pump in the Ford focus
Could you please post the dimensions (Length/Width) of the access hole you cut? Thanks!
I gotta change mine just because the duel gauge does not work. Engine light on because of this. Not pass inspection. Going to cut hole in floor. I am semi disabled. cant work underneath. thanks
Alright, good luck. Don't blow yourself up. Wouldn't want you to become fully disabled.
Great vid. Is that a diesel (gazoline)?
Gasoline.
is there any problems with the head that you took off of it???? i need a head. my 00 ford focus needs one.
Ah the oul grinder sorts everything hahaha on top of the fuel tank crazy bastard
Jaguar has the S- Type pump what kind does the 02 focus use?
Anyone ever changed the egr tube that goes from the front of the engine to the back?
so what do you have total into the car
Yep. This is not the only Ford that doesn't have the hatch. Taurus's are the same. The fuel pump barely lasted 110,000 miles, not a long service life. My 87 Toyota hasn't had the hatch unscrewed in 328,000 miles.
How much they charge u for the pump ? Why not just put whole module in your car ? Thanks