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Discussion Starter #1
Hey guys,

Long time since I've been around (life busy that way). Posting here with a half-tutorial half-problem and solution seeking post.

Randomly one day this week I noticed a small blue puddle under the passenger side of my 2005 ZX3 behind the passenger front wheel on my garage floor. Obviously my windshield washer fluid, I figured my tank had cracked or the grommet was leaking due to age (the thing is nearly 15 years old anyway). Info on MK1.5's is lacking here, but WD40's original tutorial works the same way, just on the passenger side and not driver's side. :)

So I pulled the wheel and inner fender to expose the reservoir and pump (which on MK1.5's it's on the passenger side)to find my leak was actually originating from the seam where the top and bottom parts of the pump meet, and not a cracked reservoir, hose, or bad grommet. The tank is also routed UNDERNEATH the HARD A/C lines. Brilliant move Ford.

There's no way to really get the tank out without ripping out the A/C lines, which are attached to brackets that are rivetted to the body. I can post a pic when I get home from work for anyone curious, but really there's no way to get much clearance in there to move the tank to get enough room to pull the pump. Somehow I managed to get the old pump out by prying around, but reinstallation will be interesting when I get my replacement part....

Since information on the washer pump removal/replacement for 2005-2007 Foci is sparse here, I figured I'd share my unique experience in that:

1. My leak was actually from the pump housing itself (in between black and white pieces); not the tank or grommet.

2. The 2005-2007 Focus with A/C routes the hoses over the tank inside the fender with riveted brackets that can't be removed unless you drill them out.

Anyone have experience/tips with the 2005-2007's in regards to this? Am I the only one that was lucky enough to develop a leak at the pump housing itself? Only way I can see to get more room would be as stated to pull the A/C lines, or take a few fender bolts out the top to pull it away from the housing.
 

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I think what you've experienced is similar to what I saw at a local pick n pull yard.

You have to remove the fender but then repair is simple enough. I found four mk1.5 foci at my pick n pull all missing their passenger fender and had the washer bottle pulled, all missing their pumps, none having the AC lines touched.

Sent from my Moto G (5S) Plus using Tapatalk
 

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Discussion Starter #3
Once the wheel and inner fender has been removed, it's not too much trouble to remove the actual fender itself really. But it's ridiculous that that is required, and you'll mess up the paint lines around the bolts if it's never been removed. The only reason I can fathom that they relocated the tank from the driver to passenger side, is that it interfered with the real estate they needed for the Visteon Lifetime air filter apparatus.

Both terrible decisions (for the consumer anyway.....).
 

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2. The 2005-2007 Focus with A/C routes the hoses over the tank inside the fender with riveted brackets that can't be removed unless you drill them out.

Anyone have experience/tips with the 2005-2007's in regards to this? Am I the only one that was lucky enough to develop a leak at the pump housing itself? Only way I can see to get more room would be as stated to pull the A/C lines, or take a few fender bolts out the top to pull it away from the housing.
focallocal,
The riveted on brackets are only spring clips to hold the lines. The brackets/clips themselves do not need be removed - the lines can easily be snapped out/into the clips. See attached pics (from when I replaced all my AC components/lines/hoses on my 2002 wagon).

What I cant tell you is if after you unclip the lines whether that will give you the room you need.

Good luck
Paul
 

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Discussion Starter #5
Yep, was able to reach the top bolt of the washer bottle by moving the accumulator hose, but still not enough to really make a difference. That side is the stiff side of the AC system, so the accumulator would have to come out, plus all the other hose tabs. Less work to just pull the fender unfortunately.

In 14 years of ownership, there's been very few gripes I have with these little cars.

1: The armrest sucks. 2: The PCV hose is dumb, and why is it there? 3: Why oh why is the washer bottle there? 4: Why is the alternator there? 5: Why did you put sticky rubber on my HVAC blend doors?

Still can't complain; I've spent a grand total of $40 in parts beyond routine maintenance ($4 wiper relay, $17 PCV hose, $3 RTV to seal taillights, now $16 washer pump). [hihi]
 
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