focus fuel pump replacement

[sierraman]

Due to replace the fuel pump on a 1.6 mk1 Focus, I understand I'm to drop the fuel tank, is this job a real PITA on the driveway? I've heard of people cutting a hole in the floor above under the seat but how's this work?

[Stixy]

Back end up as high as possible and drop the tank , They can be done through the floor but kink a pipe and it will leak   . Before you fit the new pump check you have all the O rings out of the outlets on the old pump as often they dont come out on the pipes 

[sierraman]

I did ponder the idea of cutting a hole above the pump, swapping the pump, then going down the breakers, cutting a bigger patch out then riveting that in its place. Sounds easier?

[twosmoke300]

I've cut the floor out on customers cars who don't want to pay to drop the tank . Sikaflex the metal back in and wear gloves when changing the pump cos the cut edges will be like razors

[sierraman]

So I don't need to fuck about heading down to the breakers to cut a floor out to patch it. Just sika it back in? Once I've hoyed the patch out is it an easy job?

[mrbenn]

Interesting thread on it here, think it'll be for the 2.0 but it gives some pointers at least:

 

http://www.focusfanatics.com/forum/general-technical-chat/276213-how-cut-fuel-pump-access-panel-door.html

 

Out of interest how has yours failed? Will it not start at all?

[fordperv]

I did ponder the idea of cutting a hole above the pump, swapping the pump, then going down the breakers, cutting a bigger patch out then riveting that in its place. Sounds easier?

I did the this exact thing except on the patch I cut out I welded a strip of metal either side and fixed it back on with them, really easy but my tip is don't go balls out with the grinder when cutting, take your time use a 1mm cutting disk, ease it along thinning the metal on your marked lines until your almost all the way through then prise it away with a screwdriver, i say this because parts of the tank are close to the floor where your cutting

[sierraman]

I was going to use the dremel, with the cutting disc. If I go gentle with it should be able to pride the lid back. Once I've fecked about with that, is replacing the pump easy enough? How big do I need to go with the hole?

[sierraman]

Interesting thread on it here, think it'll be for the 2.0 but it gives some pointers at least:

 

http://www.focusfanatics.com/forum/general-technical-chat/276213-how-cut-fuel-pump-access-panel-door.html

 

Out of interest how has yours failed? Will it not start at all?

It'll start but keeps blowing the fuse. To get me home I had to chuck a 20 amp fuse in as opposed to the 15 amp. Before I set about all this however there's nothing to be lost in replacing the Relay

[steveo3002]

would anyone else worry about grinding the hole in the floor ?  good chance of a explosion no?

[sierraman]

Yeah that is a worry. I'm going to swap the relay with a few from breakers, then if that doesn't work set about swapping the pump. I might have use of a ramp, so dropping the tank might not be too bad if I've got that option. Hopefully it might be a duff relay...

[steveo3002]

spose could use some hand niblers 

[fordperv]

I was going to use the dremel, with the cutting disc. If I go gentle with it should be able to pride the lid back. Once I've fecked about with that, is replacing the pump easy enough? How big do I need to go with the hole?

That link from Mr Benn is a good guide to the size of hole needed, as soon as you have your hole, there is a retaining ring that needs spinning off, I needed to knock the one I did with a hammer and screwdriver to start it off, the fuel pipes have quick release clips that may break on removal,

 

What I've seen mostly is the power wires to the that sit in the tank which I think may be the case for you, it sounds like they are shorting occasionally popping the fuses, it's a shame I didn't still have my old phone I'd put some pictures up

[sierraman]

Plan of action then... Check for chafing on the 12v supply to the pump, replace relay, then see about repairing the pump, I'm going to drop the tank on reflection, if I've got the use of a lift I might as well drop the tank a foot or so and do it properly.

 

If it is the pump, I just need the actual pump itself as opposed to the whole assembly with the sender and float etc.

 

So next stop is the breakers at weekend...

[Joey spud]

Dont over look the obvious like has the fuel cut off switch been tripped.

 

If the fuse is ok then banging on the base of the tank with your hand while some one cranks it over often gets them going again.

 

I think a lot of pump failures are down to old restricted fuel filters causing excess current draw (should be about 5 amps) or the tank only ever has a tenners worth of fuel in it so the pump isn't submerged and rattles around.or just old age the pumps motor gets a bit tight and blows the fuse.

 

Its easy enough to check the circuit just tip the seat base and get to the wiring to the pump and check there is a live and earth present when you ignition on and when you crank over.

 

I have seen many a fiesta with a three sided roughly cut opening that has been folded over on its uncut edge to gain access to the pump,then folded back down again and sealed with gaffa tape.

Does seem strange why Ford didn't fit an access grommet like most other car makers do.

[Stixy]

Check the electrical connector on the pump unit  i have changed a few of these where they have had grotty pins and caused trouble  ,  

[sierraman]

Update on this. Swapped the relay a month or so ago, no problems until this afternoon and the fecker did it again. I'm going to order a £20 fleabay pump and then drop the tank a foot or so and whip the top off the unit. Sounds like that'll be a barrel of laughs!

[hairymel]

dropping fuel tanks is fraught with horror.

 

the most effective but less pretty way is to cut the floor

 

focusfanatics link shows where to cut - i wouldn't use  power tools, aviation snips are ideal.

 

just tape a piece of ally or similar over the hole afterwards.

 

wear good gloves or bleed like a stuck pig.

 

i have done loads of fiestas and 1 focus this way

[twosmoke300]

Good luck dropping the tank on a focus mk1 . The filler neck will have the structural ridgidity of a bran flake and you have to drop the subframe a bit to replace it .

As suggested above get busy with the tin snips

[sierraman]

Reconsider then. The tinsnips idea sounds a bit safer thinking on. If I get the hole started with the grinder then switch to the snips to get the hole going... Might be a daft question but where's the best place to give it a touch with the grinder to get the hole started?

[Junkman]

Whoever came up with the idea to put a fuel pump into a tank should be executed in public.

[sierraman]

Or would I be better just giving the hole a few passes with the grinder until it's nearly through then pry it up? How much space is between the boot floor and the pipes?

[dieselassist]

my brothers 380km 2004 focus has a 'lazy fuel pump' - it was chronic to drive, chugging about n near cutting out on corners, n a hard start in the morning... I changed the fuel filter - which is similiarly a faff with 'big hands' to change - looked like the old one was the original motorcraft one- it was full of black gunge- completely clogged...

doing this, along with some injector cleaner, and keeping the tank above a quarter at all times, has improved things no end - still takes two cranks over in the morning to start, but otherwise its fine to drive...

[sierraman]

Right got it marked out. I'm going in for the cut. I know it's suggested using tin snips to cut the floor but if I use the Dremel to shallow cut the panel out how big a risk do I have of a fire or resultant explosion?

[dieselassist]

...it'll take several days, many mini cutting discs n 2 or 3 dremmel tools to cut out a panel that size - if your intent on cutting the floor, use a grinder n 1mm cutting  'zip discs' - as the yanks call them - it takes a bit of patience but you can 'score down' the cut along the lines you've made, till the edge of the disc has cut through...

 

...if your worried about fire, your best off just dropping the tank with its rear end hoiked up in the air...

[sierraman]

I've them reinforced cutting discs. Plus the Dremel I have is mains op. It goes through in no time, my concern is the Sparks and my drive resembling the General Belgrano. Is this practically likely that's what I'm saying?

[hairymel]

i would guess others have cut the floor with a grinder and lived but get a £10 pair of snips and cut out from the grommet hole is my advice.

 

the pipes are danger close to where you are cutting and it would be very easy to nick one. 

 

it's only an hour job and you've been waffling for a fortnight!

 

stop fucking about and get it done 

[sierraman]

I know, I'm one of life's great thinkers. Fuck it, I'll drop the back wheels in and go for it. My question was, is the fuel system sealed enough to prevent a stray spark causing me to hold the remainder of this conversation via a seance?

[hairymel]

unlikely to 'explode' straight away -  but if you cut a pipe it will burn to a crisp in front of you 

[Dead_E23]

If you pull that grommet out, you'll have a better idea how much clearance there is under the panel and you might see where the pipes run.   

Even a proper grinder with a slitting disk wouldn't plunge thorough that like wet tissue paper, so I reckon you should have no difficulty making a controlled shallow cut with a Dremel.     Making a sufficiently deep and long one might be the challenge.

 

For £35 you can get a Bosch 4 1/2" grinder that'll make it a piece of piss and that you can do proper jobs with.  I'd do that.