Removal and Installation

WARNING: This page is about a different car, the 2006 Mercury Milan, 2006 Lincoln Zephyr, and 2006 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.

WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.

WARNING: The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery ground cable from the battery to minimize the possibility of an electrical spark occurring, and possibly causing a fire or explosion if fuel vapor or liquid fuel are present in the area. Failure to follow these instructions can result in personal injury.

WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel causing personal injury or a fire hazard.

WARNING: The fuel in the tank may be pressurized. Remove the fuel tank cap slowly. If a hissing sound is heard, wait until the condition stops before removing the fuel tank filler cap. If these precautions are not followed, fuel may spray and cause personal injury.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
Release the fuel system pressure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Release the fuel tank filler cap and position it aside.

CAUTION: Upon removing the special tool, the fitting on the end of the hose can become detained by the one way flapper valve. Carefully remove the hose using a gentle agitating motion to avoid detaching the hose from the fitting.

NOTE: The special tool must be inserted into the fuel tank filler pipe until the fitting on the end of the hose enters into the fuel tank spout, opening the one way flapper valve.

Fig 1: Identifying Special Tool

Courtesy of FORD MOTOR CO.

Insert the special tool into the fuel tank filler pipe.

NOTE: This step will remove approximately 1/8 tank of the fuel from a completely full fuel tank and the majority of any residual fuel in the fuel tank filler pipe.

Attach the fuel storage tanker to the special tool and remove as much fuel as possible from the fuel tank and fuel tank filler pipe.
Remove the 3 fuel tank filler pipe retaining screws.
Disconnect the rear wheel splash shield.
Remove the fuel tank filler pipe vapor tube from the fuel door pocket.

Fig 2: Locating Fuel Tank Filler Pipe Vapor Tube
Courtesy of FORD MOTOR CO.
Remove the 3 nuts and the fuel tank filler pipe heat shield.
- To install, tighten to 9 Nm (80 lb-in).
  
  Fig 3: Locating Fuel Tank Filler Pipe Heat Shield Nuts
  Courtesy of FORD MOTOR CO.
Remove the fuel tank filler pipe bracket retaining nut.
- To install, tighten to 9 Nm (80 lb-in).
  
  Fig 4: Locating Fuel Tank Filler Pipe Bracket Retaining Nut
  Courtesy of FORD MOTOR CO.
Release the 2 fuel tank filler pipe vapor tube retaining clips.

NOTE: Place absorbent pads in the general work area in case of fuel spillage.

Release the clamp and disconnect the fuel tank filler pipe hose from the fuel tank.
- To install, tighten to 4 Nm (35 lb-in).
Remove the fuel tank filler pipe assembly from the vehicle.
To install, reverse the removal procedure.