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Discussion Starter #1
Hey guys I had an issue around christmas with my car cutting out and dying. I thought it was fixed but it seems it is not. You can read all about it here

https://www.focusfanatics.com/forum/mk1-focus/809243-2001-zetec-dying-3.html

After it happening again I changed the fuel filter again this week. 150 miles and about 4 hours of driving it died on me again on the way to work today. Waited maybe a minute and it fired up. At this point I am leaning to a new pump. Its got a new filter but that doesnt mean the tank isnt dirty. Maybe the prefilter is plugged. Maybe the pump is on it way out. That would baffle me cause I went 4 months problem free and now I am back to it. Either way I be having to take a look in the tank it seems.

So I have a few questions. Before I attempt this what is the easiest way to check fuel pressure? Are these cars like my cobra, a returnless style where the pump speeds up and down to give the fuel the car needs? If so is there a fuel rail pressure sensor I can monitor fp with? And when it comes to the pump I am thinking I will go under the seat. My car is very rusty, I dont think I could get the exhaust off to drop the tank down. Anyone have a diagram of where to cut? Also if the tank is dirty whats the best way to clean it out?

Sorry for the long post I am not sure what else could be wrong with it. If there is anything else to check please let me know. Can my gas cap or something affect it? My car no longer has the heat shield under it. I dont think that should matter but thought id point it out.

Thanks in advance from a guy just trying to get his work car running so his wife doesn't kill him.
 

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It will work. You need to remove the snap-in ring (at least pieces of it) that the old pump snapped into, the new one doesn't use it and needs to sit flat on tank floor.
 

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

Look at the 6th pic there and how close the evap line comes in that corner (pass side rear). VERY easy to nick the line cutting and then you have an evap code popping up. Lower the tank about one inch by getting under car to unscrew the one strap bolt, that gives you a bit of room to not hit that line.


https://www.fordcontour.org/topic/10804-returnless-fuel-pump-installation-instructions/

On a Contour but the same. Look down further on page, you see the expensive tool but others have used a razor blade or very sharp knife.
 

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Be advised the fuel line into the top of the pump module can be damaged as they are hard to get out. 3 tabs on it. I use like Harbor Freight cheap $4 needlenose with the last 1/8" bent inwards of both the tips, then use that to compress the tabs on the side while using a pick or small screwdriver tip to compress the top one, then the line comes out in seconds. The other way (ANY other way) takes forever and usually ruins the line, but thinking they give you a new one with the pump because people usually break the old one.
 

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Discussion Starter #7
Ok focus friends I replaced my pump. Same problems. I have felt the car buck twice and it has died once about 30 seconds after i started it. I put it in reverse and it died right after. Started back up 5 seconds later. No codes still. Where should i look next? A buddy said he read about voltage regulators going bad in these cars. But the only symptoms i seen from the list when I googled is the engine dying. I havent noticed my lights dimming on the dash. My headlights are led so they dont take much juice anyway. Battery has never been dead. Not sure where else to start. Any recommendations welcome. Thanks.

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Basic tuneup being off will let them die over and over all day long. There is a PCV hose in the REAR of engine that can go bad to do it too. PCV valve is up front, short rubber hose to steel one bolted to driver end of head then the final rubber from the steel line to back of intake and the problem commonly in that last piece of hose. Vac leak that then lets engine die over and over.
 

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Discussion Starter #9
I replaced that a few years ago. A friend who is a mechanic suggested maybe the ignition module. I had a wire on the plug break last year. Replaced it with a new plug. I guess it wouldnt hurt to take a look at the module and wiggle some wires

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Discussion Starter #11
Gotcha. I wiggled it last night the car didnt die or anything. It is pretty oily on the bottom. Was pretty hot as well. Idk if either of them would affect it? Please let me know if that would affect the coil. Also what else should I look in to? Thanks just trying to get this running right

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