Replacing The Fuel Pump In A 2006 Ford Focus Zx3

Replacing the fuel pump on a 2006 Ford Focus ZX3 can be a challenging task. The fuel pump is responsible for delivering fuel from the tank to the fuel injectors, and it is typically located inside or outside the fuel tank. Before beginning the replacement process, it is recommended to disconnect the battery to reduce the risk of fire. Additionally, it is important to ensure that the fuel tank is almost empty, as a full tank will make the process more difficult. The next steps involve removing the fuel tank, which may require cutting an access panel or lowering the tank to access the pump. It is crucial to take precautions and follow the appropriate procedures to avoid any potential hazards. Once the fuel pump is accessible, it can be replaced by following the manufacturer's instructions. It is also advised to replace the fuel filter and the intake screen for in-tank fuel pumps during this process.

Removing the fuel tank

To remove the fuel tank from a 2006 Ford Focus ZX3, you will first need to locate and pull the fuse for the fuel pump (#12). Then, get in the car and start the engine. Let it run until it dies, and repeat this process one or two more times to depressurise the fuel line. Put the fuse back in and detach the negative terminal on the battery.

Now, you can either unbolt the exhaust from the rear of the flex pipe and pop it off the hangers, or you can jack up the rear of the vehicle. If you choose to jack up the vehicle, it is recommended to also remove the rear passenger-side wheel.

Next, slide under the car and locate the fuel tank and the heat shield that protects it from the exhaust. Remove the retaining tabs that hold the heat shield in place using pliers. You may need to cut the heat shield to fully remove it.

Now, locate the fuel filter and the lines surrounding it. Detach the lines and remove the fuel filter assembly. Be prepared for gasoline to spill from the filter and lines.

At this point, you will need to disconnect three hoses in order to drop the tank: the large clamp on the bottom (the filling hose) and two special Ford clips on the top. Once you have disconnected these hoses, you are ready to drop the tank. It is recommended to have an extra set of hands or a jack to support the tank as you do this.

The tank is held by a strap with three points of contact. You only need to disconnect one of these: the one towards the front of the vehicle is held by a bolt. Loosen this bolt and support the tank before completely removing it.

With the tank supported, remove the bolt and slowly lower the tank. Disconnect the two electrical connections on top of the tank: one on the top of the pump and the other directly opposite on the driver's side. Also, locate and remove the evap line, which is tucked into a crease on the top of the tank.

Now, you can fully lower and remove the tank. Make sure to check that everything in the rear is ok as you slide the tank out.

Disconnecting the battery

To begin, locate the negative terminal on the battery. This is usually marked with a "-" symbol and is often black, in contrast to the positive terminal, which is usually red. Once you have located the negative terminal, you will need to detach the cable connecting it to the battery. This can be done by loosening the nut or bolt that secures the cable, usually with a socket wrench or standard wrench. Make sure you have a safe place to store the cable, away from the battery, to avoid any accidental contact or arcing that could cause a spark.

It is also important to note that you should avoid touching any metal parts of the car with your wrench or any other tools when detaching the battery cable. This is because the battery is connected to the car's body, and any contact with metal parts could cause an electrical short, potentially leading to damage to the car's electrical system or even a fire.

Additionally, it is recommended to wear protective gear, such as safety glasses and gloves, when working on the battery to protect yourself from any battery acid that may be present.

By following these steps and taking the necessary precautions, you can safely disconnect the battery on your 2006 Ford Focus ZX3, ensuring a safer environment for you to proceed with the fuel pump replacement.

Removing the access cover

To remove the access cover of your 2006 Ford Focus ZX3, start by locating and pulling the fuse for the fuel pump (#12). Then, get in the car and start the engine. Let it run until it dies, and repeat this process one or two more times to depressurise the fuel line. Put the fuse back in and detach the negative terminal on the battery.

Next, you can either unbolt your exhaust from the rear of the flex pipe and pop it off the hangers, or you can jack up the rear of the vehicle. If you choose to jack up the vehicle, make sure to chock the wheels for safety.

Now, remove the rear passenger-side wheel. Slide under the car and locate the fuel tank and the heat shield that protects it from the exhaust. That heat shield needs to be removed. To do this, you can either unbolt the exhaust from the flex back and remove all the hangers, or you can cut the heat shield. If you choose to cut it, first remove all the retaining tabs that hold the heat shield in place. You can grab them with pliers and turn them off, as they are threaded. Then, cut out the small corner of the heat shield where it hangs up on the exhaust hanger. This will allow you to rotate the heat shield out.

With the heat shield removed, locate the fuel filter and the lines surrounding it. You will need to detach these lines and remove the fuel filter assembly. Make sure to have rags and safety glasses on hand, as there will be gas in the filter and lines.

Now, locate the three hoses that need to be disconnected in order to drop the tank: the large clamp on the bottom (the filling hose) and two special Ford one-time-use clips on the top. Once you've disconnected these, you're ready to drop the tank. You may want an extra set of hands or a jack to support the tank, as you don't want it to fall out. The tank is held by a strap with three points of contact; you only need to disconnect one of them. Loosen the bolt at the front of the vehicle and support the tank before completely removing the bolt.

With the tank supported, slowly lower it and remove the two electrical connections on the top of the pump before fully removing the tank. Now, you can proceed to replace the fuel pump.

Disconnecting the fuel lines

Firstly, locate and remove the fuse for the fuel pump. This will depressurise the fuel line. Put the fuse back in once the line is depressurised. Next, detach the negative terminal on the battery. At this point, you can choose to unbolt the exhaust from the rear of the flex pipe and pop it off the hangers to allow for easier manoeuvring. If you do not wish to do this, you can proceed to jacking up the rear of the vehicle.

Once the car is securely jacked up, remove the rear passenger-side wheel. Slide under the car and locate the fuel tank and the heat shield that protects it from the exhaust. Remove the retaining tabs that hold the heat shield in place using pliers. You may need to cut the heat shield for easier removal, especially if it hangs up on the exhaust hanger. Be sure to wear safety glasses and gloves for this task.

Now, locate the fuel filter and the lines surrounding it. You will need to detach these lines and remove the fuel filter assembly. Be prepared for the release of fuel from the filter and lines. Have rags and safety glasses on hand to catch any spills and protect your eyes.

At this stage, you will see three hoses that need to be disconnected to drop the tank: the filling hose and two special Ford clips. The filling hose is secured with a regular hose clamp, while the other two are held in place with one-time-use clips. These clips may be facing away from you, so follow the lines to locate them. They are typically found closer to the wheel well. Once you have accessed them, carefully disconnect the hoses.

With the hoses disconnected, you are now ready to drop the tank. It is recommended to have an extra set of hands or a jack to support the tank as you do not want it to fall. Loosen the bolt on the strap that holds the tank, and slowly lower it to access the electrical connections on top. Disconnect these electrical connections before completely removing the tank.

Now that the tank is lowered, you can also locate and detach the evap line, which is usually tucked into a crease moulded into the top of the tank.

By following these steps, you will have successfully disconnected the fuel lines on your 2006 Ford Focus ZX3, allowing you to proceed with replacing the fuel pump. Remember to take all necessary precautions when working with the fuel system to prevent any safety hazards.

Draining the fuel

To drain the fuel from your 2006 Ford Focus ZX3, you will first need to remove the fuel tank. Before doing so, it is recommended to plan ahead and keep an eye on your fuel level, aiming to have very little in the tank when you begin the process. If your fuel gauge needle is sitting on the red line, you will probably have between 1-2 gallons left in the tank.

Once you have ensured that your fuel tank is almost empty, follow these steps:

• Jump into your car and start the engine. Let it run until it dies, then repeat this process one or two more times. This will help to depressurize the fuel line.
• Put the fuse back in and detach the negative terminal on the battery.
• Jack up the rear of the vehicle. It is recommended to use the tallest jack and stands you can find to get the car as high as possible.
• Remove the rear passenger-side wheel.
• Slide under the car and locate the fuel tank and the heat shield that protects one side of it from the exhaust.
• Remove the heat shield by unbolting the exhaust from the flex back and undoing all the hangers so you can move the exhaust and maneuver the heat shield around it. Alternatively, you can cut the heat shield, but this will need to be done carefully to avoid damaging any other components.
• Disconnect the fuel lines and remove the fuel filter assembly. Have rags and safety glasses on hand, as there will be fuel in the filter and lines.
• With the fuel lines and filter assembly disconnected, you are now ready to drop the tank. It is recommended to have an extra set of hands or a jack to support the tank, as you don't want it to fall.
• The fuel tank is held by a strap that has three points of contact. You only need to disconnect one of these by loosening the bolt at the front of the vehicle and supporting the tank before completely removing the bolt.
• With the tank supported, slowly lower it and remove it from the vehicle.
• Use a siphon to remove the remaining fuel from the tank.

Please note that working with the fuel system is dangerous, and there is a risk of fire. Always take the necessary precautions and have your vehicle repaired by a professional if you are not experienced in auto repair.

Frequently asked questions