Fuel - Fuel Fill Slow Or Early Shut Off
TSB 07-8-104/30/07
FUEL FILL - SLOW/EARLY SHUT OFF
FORD:
2005-2007 Focus
ISSUE
Some 2005-2007 Focus vehicles may exhibit a slow or difficult fuel fill, spit back or early pump shut off condition when refueling. This concern may be due to spider nests causing a restriction in the fresh air hose connected to the fuel filler housing and not allowing the fuel system to vent properly.
ACTION
Follow the Service Procedure steps to correct the condition by installing a new spider screen fitting onto the fresh air hose.
SERVICE PROCEDURE
1. Remove the Fuel Filler Pipe assembly as outlined in the Workshop Manual (WSM), Section 310-01.
a. If a blockage is found in the fresh air vent tube, proceed to Step 2.
b. If no blockage is found in the fresh air vent tube, do not proceed with this TSB. Refer to Workshop Manual, Section 310-00 for normal diagnostics.
2. Remove 90° end fitting from end of vent hose and discard. (Figure 1)
3. Insert a suitable flexible tool into the fresh air/vent hose and rotate the tool to dislodge the spider nest.
4. Blow out the fresh air/vent hose with compressed air.
5. Remove Fuel Filler Housing from vehicle body.
a. Remove retaining push pin at rear of fuel filler door housing.
b. CAREFULLY push outwards from backside of fuel filler housing to dislodge from body.
6. Cut off nipple from back of Fuel Filler Housing. (Figure 2)
7. Copy Figure 3 as the pattern, cut out center and overlay onto back of filler housing.
NOTE
WHEN COPYING THE PATTERN, INSURE PRINTER AND VIEW SETTINGS ARE SET AT 100% TO INSURE PROPER SCALING OF TEMPLATE. TEMPLATE HOLE NEEDS TO BE 0.984" +/- 0.2" (25 MM +/- 0.5 MM) FOR PROPER FITTING RETENTION.
8. Using a rotary tool, "CAREFULLY" enlarge the hole to match the pattern of 0.984" +/- 0.2" (25 mm +/- 0.5 mm).
NOTE
DO NOT ENLARGE HOLE BEYOND 0.984" +/- 0.2" (25 mm +/- 0.5 mm) OR SPIDER SCREEN FITTING WILL NOT HAVE PROPER RETENTION WHEN INSTALLED.
9. Remove any burrs or flashings from the opening using a suitable file.
NOTE
CARE MUST BE TAKEN NOT TO ROUND INNER EDGE OF HOLE AS IT IS USED FOR SPIDER SCREEN FITTING RETENTION.
10. Insert spider screen fitting into opening until retaining tabs are fully seated. (Figure 4)
11. Install modified fuel filter housing into vehicle body.
a. Snap housing into body opening.
b. Install the previously removed retaining push pin until properly seated.
12. Install fuel filler pipe as outlined in WSM, Section 310-01.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage
IMPORTANT:
Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.
OPERATION DESCRIPTION TIME
070801A 2005-2007 Focus: Modify 0.9 Hr.
Fuel Filler Housing And
Install A New Spider
Screen Fitting (Do Not Use
With 9034A, 9030A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
9032 55
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