Fuel System - General Information - Fuel Additive System Filling and Bleeding

Focus 2004.75 (07/2004-)

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General Procedures

General Equipment

WARNINGS:

This procedure involves fuel additive handling. Be prepared for fuel additive spillage at all times and

always observe fuel handling precautions. Failure to follow these instructions may result in personal

injury.

Eye, hand, ear protection and protective clothing are required to be worn during any general service

or removal and installation procedures of fuel additive system components. Failure to follow this

instruction may result in personal injury.

In case of fuel additive fluid contact with the skin or the eyes, flush immediately with water for a

minimum of 15 minutes and seek prompt medical attention. Failure to follow these instructions may

result in personal injury.

If fuel additive fluid is swallowed, call a physician immediately. Rinse mouth immediately with water,

do not induce vomiting. Failure to follow these instructions may result in personal injury.

Always provide adequate ventilation when working on the fuel additive fluid system or related

components. Failure to follow these instructions may result in personal injury.

Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel

related components. Highly flammable vapors are always present and may ignite. Failure to follow these

instructions may result in personal injury.

CAUTIONS:

Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as

possible. Foreign matter from work on clutches, brakes or from machining or welding operations can

contaminate the fuel system and may result in later malfunction.

After the filling procedure has taken place, make sure the fuel additive refill kit and pipes are stored

in a dry and secure area away from dirt. Foreign matter from work on clutches, brakes or from machining

or welding operations can contaminate the fuel additive fluid.

Transmission Jack

1. Remove the right-hand rear wheel and tire.

For additional information, refer to: Wheel and Tire (204-04

Wheels and Tires, Removal and Installation).

2. Raise the vehicle.

3. Remove the fuel additive tank overflow pipe quick release

coupling blanking cap. � Release the locking tang.

4. Install the fuel additive refill kit overflow pipe to the fuel tank.

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5. Remove the fuel additive tank filler pipe quick release coupling blanking cap.

� Release the locking tang.

6. NOTE: Make sure the fuel additive tank filling kit additive

container is positioned lower than the fuel additive tank.

NOTE: Make sure the fuel additive tank filling kit additive

container valve is in the closed position. Connect the fuel additive tank filling kit filler pipe to the fuel

additive tank filler pipe.

7. Attach the fuel additive tank filling kit hook, net and overflow

container to the underside of the vehicle. � Insert the additive tank filling kit overflow pipe into the

overflow container.

8. NOTE: Make sure that the fuel additive tank filling kit is

maintained in a horizontal position. Using a suitable transmission jack, raise the fuel additive tank

filling kit additive container above the fuel additive tank.

9. CAUTION: Do not allow air to enter the fuel additive

filler pipe.

NOTE: Make sure the fuel additive tank filling kit additive

container is positioned above the fuel additive tank.

NOTE: Make sure the fuel additive tank filling kit additive

container valve is in the open position.

NOTE: If the fuel additive tank filling kit additive container

empties during the filling procedure. Close the fuel additive

tank filling kit additive container valve, lower the fuel

additive tank filling kit additive container and disconnect the

filling pipe. Connect the filling pipe to the new fuel additive

tank filling kit additive container, raise the fuel additive tank

filling kit additive container and then open the fuel additive

tank filling kit additive container valve and continue to fill the

fuel additive tank. Open the fuel additive tank filling kit additive container valve and fill the fuel additive tank until fuel additive fluid is seen escaping

from the fuel additive tank overflow pipe.

1. Close the fuel additive tank filling kit additive container valve.

10. Lower the fuel additive tank filling kit additive container below the fuel additive tank to stop the flow of fuel additive fluid.

� Open the fuel additive tank filling kit additive container

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valve to allow the fuel additive fluid to drain back to the fuel additive tank filling kit additive container.

11. NOTE: Make sure the fuel additive tank filling kit additive

container is positioned below the fuel additive tank. Disconnect the fuel additive tank filling kit filler pipe from the fuel

additive tank filler pipe. � Close the fuel additive tank filling kit additive container

valve.

12. Install the fuel additive tank filler pipe quick release coupling

blanking cap.

13. Remove the fuel additive refill kit overflow pipe from the fuel

additive tank. � Allow the fuel additive fluid to drain back to the fuel

additive tank filling kit additive container.

14. Install the fuel additive tank overflow pipe quick release coupling

blanking cap.

15. Lower the vehicle.

16. Connect the fuel additive tank filling kit filler pipe to the fuel

additive tank filling kit overflow pipe using the double nipple. 1. Open the fuel additive tank filling kit additive container

overflow valve to allow the additive fluid to drain back to

the fuel additive tank filling kit additive container.

17. CAUTION: After the filling procedure has taken place,

make sure the fuel additive tank filling kit additive container

and pipes remain connected together and are stored in a dry

and secure area away from dirt. Foreign matter from work

on clutches, brakes or from machining or welding operations

can contaminate the fuel additive fluid.

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NOTE: If the malfunction indicator lamp (MIL) and or the

powertrain control lamp (PCL) are illuminated, driven by an

empty or low level additive tank, the fuel additive system

must be reset using the diagnostic tool. If neither the MIL or

PCL lamps are illuminated in the instrument cluster the fuel

additive system can be reset manually. Reset fuel additive system using Ford Diagnostic Tool.

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