To accomplish this, the PCM sends instructions to the fuel pump driver module, located under the passenger seat. What about replacement number two, and now number three? The Focus has a returnless fuel system, so the fuel pump supplies only enough fuel volume and pressure to meet the engine's current needs/no more, no less. That probably takes care of fuel pump module number one. He'll have to check with a dealer once you've sorted out the repeat fuel pump failure problem. Ford may even cover the customer's pump module replacement costs. You can find additional information about the fuel pump module replacement procedure in Ford TSB 04-5-6. So if your customer's vehicle fits the build criteria, it's entirely possible that the original pump could have died of natural causes. Ford has released a replacement fuel pump module, to address problems with it on a specific range of 2000-02 Focus vehicles built at two different Ford assembly plants. Let's start with the first fuel pump, George. Each pump has exhibited the same loss of fuel pressure under acceleration at the end of its life, but seemed fine at the beginning. A second fuel pump module was installed and it lasted about the same length of time. The vehicle was returned to the customer, but he came back about three months later with the same symptoms. I installed a new fuel pump module and the symptoms were completely eliminated.
A subsequent fuel pressure test revealed that pressure was dropping as low as 8 to 10 psi while the loss of power/miss was occurring. The engine would miss and lose power at this speed, but straighten out again after shifting into Drive. I was able to duplicate the condition by shifting the transmission into 2nd gear and running the engine at 3500 to 4000 rpm. The engine would run fine under light to moderate acceleration, while cruising and at idle. The customer's original complaint was a lack of power under heavy acceleration. My customer has a 2002 Ford Focus 2.0L SOHC with about 35,000 miles on it.