How to Install a Fuel Tank in a Ford Focus

Written by ehow cars editor
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The Ford Focus is among the more recent additions to Ford's car arsenal. The Focus is considered a worldly car with an international appeal for both American and European buyers. Installing a fuel tank into all Focus models is easy enough for anyone to do in whatever part of the world. Learn what procedures you need to follow to ensure proper fuel tank installation.

Skill level:

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Things you need

  • Siphoning hose
  • Fuel container
  • Jackstand
  • Torque wrench
  • Floor jack
  • Fuel tank
  • Screwdriver

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  1. 1

    Take off the fuel filler cap and disconnect the negative car battery cable. Put in a siphoning hose to empty the gas out of the fuel tank into an approved container; set the container aside.

  2. 2

    Put the car on a jackstand and remove the car's rear wheel nuts with a torque wrench. Take off the wheels. Remove all wires and fuel hoses from the fuel tank. Unhook the tank straps and remove the tank bolts. Lower the tank to the ground with a floor jack.

  3. 3

    Inspect your fuel tank carefully before positioning it underneath your Focus' trunk. Attach the fuel lines to the top portion of the tank, and connect the fuel pump/gauge sender wiring plug located at the top left side of the fuel tank. Check the plug to verify that all the wiring is in place before continuing to install your fuel tank.

  4. 4

    Hook the tank straps around the fuel tank and put the tank strap bolts on each end of the tank to hold it to the car's body. Place the fuel return line into the connector slot right next to the fuel filter and connect the fuel supply hose back onto the fuel filter to keep the fuel inside your fuel tank.

  5. 5

    Reattach the filler pipe and vent hoses back onto the fuel tank. Install the exhaust system mounting rubbers at the front and back of your Focus. Restore the exhaust heat shield, located at the rear of the car near the exhaust pipe. Use a screwdriver to screw in the exhaust flange nuts behind the bendable part of the exhaust pipe's front to keep it on the car's body.

  6. 6

    Install the car's rear wheels back onto your Focus. Tighten the rear wheel nuts with a torque wrench as much as possible or until the wheel nuts can't turn any further. Refill your fuel tank with the gas from your fuel container and then connect the negative battery cable.

  7. 7

    Restore pressure to your tank by putting on the fuel filler cap. Check your car for any leaks or loose wiring. If you don't see anything, take a drive to check how it runs with the new fuel tank.

Tips and warnings

  • Exercise caution when working on your car, and keep a fire extinguisher handy in case of fire.
  • Don't siphon gas out of the tank by mouth; gas is toxic to ingest. Purchase a gas siphoning kit and a fuel container to empty your fuel tank into.

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