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Removal and Installation

WARNING: This page is about a different car, the 2005 Mercury Montego, 2005 Ford Freestyle, and 2005 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Do not smoke or carry lighted tobacco or an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and can be ignited, resulting in possible 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: Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing 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: This procedure involves fuel handling. Be prepared for spillage at all times and always observe fuel handling precautions. Failure to follow these instructions can result in personal injury.

    All 

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  3. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  4. Remove the generator. For additional information, refer to GENERATOR AND REGULATOR .
  5. Remove the evaporative emission (EVAP) canister purge valve. For additional information, refer to EVAPORATIVE EMISSIONS .
  6. Detach the fuel supply tube retainer from the upper intake manifold.
  7. Disconnect the fuel supply tube-to-fuel rail quick connect coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  8. Remove the fuel tube retainer bolt.
    • To install, tighten to 20 Nm (15 lb-ft).
    9. NOTE: The fuel tube retainer shield nuts are part of the retainer shield and are not serviced separately.
  9. Remove the fuel tube retainer shield.
    • Loosen the 3 retainer shield nuts.
    • Remove the retainer shield.
  10. Disconnect the fuel vapor tube assembly valve-to-vapor tube quick connect coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  11. Disconnect the 2 fuel supply tube-to-fuel filter quick connect couplings. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .

    12. Five Hundred, Montego 

  12. Remove the rear lower seat cushion.
    • Release the latches and pull upward on the rear lower seat cushion and remove.
      Fig 1: Identifying Lower Seat Cushion Releasing Latch
      G03945904Courtesy of FORD MOTOR CO.

    13. Freestyle 

  13. Position the second row seats rearward.
  14. Remove the rear seat latching brackets.
    • Remove the latching bracket bolts.
    • Remove the latching brackets.
    • To install, tighten to 17 Nm (13 lb-ft).

    15. All Vehicles 

  15. Remove the fuel pump module access cover.
  16. Clean the surrounding area of the fuel pump module mounting flange and the quick connect couplings with compressed air.
  17. Disconnect the fuel supply tube-to-fuel pump module quick connect coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  18. Disconnect the fuel vapor tube assembly valve-to-fuel pump module quick connect coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  19. Disconnect the fuel vapor tube assembly valve electrical connector.
  20. Disconnect the fuel vapor tube assembly valve-to-EVAP canister tube quick connect coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  21. Disconnect the fuel vapor tube-to-EVAP canister quick connect coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  22. Disconnect the fuel vapor tube-to-fuel tank filler pipe vapor tube quick connect coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  23. Release the fuel tube assembly from the fuel tube retainers.
  24. Remove the fuel tube assembly.
  25. To install, reverse the removal procedure.
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