Removal and Installation

WARNING: This page is about a different car, the 2005 Mercury Mountaineer and 2005 Ford Explorer. 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 component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may 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 lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.

CAUTION: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or tubes.

CAUTION: When reusing liquid or vapor tube connectors make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube.

NOTE: During the repair or replacement of fuel-related components, all liquid and vapor fuel openings shall be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials shall be removed prior to installation.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING .
Release the fuel system pressure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
Disconnect the battery negative cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Remove the driveshaft. For additional information, refer to DRIVESHAFT .
Drain the fuel tank. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
If equipped, remove the 4 bolts and the transfer case skid plate.
- To install, tighten to 40 Nm (30 lb-ft).
  
  Fig 1: Removing Bolts And Transfer Case Skid Plate
  Courtesy of FORD MOTOR CO.
Disconnect the filler pipe vapor tube fitting. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
Disconnect the fuel vapor vent valve-to-fuel pressure sensor and tube assembly hose.
Remove the bolts and the fuel filter heat shield.
- To install, tighten to 20 Nm (15 lb-ft).
  
  Fig 2: Removing Bolts And Fuel Filter Heat Shield
  Courtesy of FORD MOTOR CO.
Remove the nuts and the fuel filter shield.
- To install, tighten to 5 Nm (44 lb-in).
  
  Fig 3: Removing Nuts And Fuel Filter Shield
  Courtesy of FORD MOTOR CO.
Disconnect the fuel filter spring lock coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
Disconnect the fuel pressure sensor and tube assembly-to-vapor tube fitting. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
If equipped, remove the 3 bolts, 2 nuts and the fuel tank skid plate.
- To install, tighten to 40 Nm (30 lb-ft).
Using a suitable jack, support the fuel tank.

Fig 4: Supporting Fuel Tank
Courtesy of FORD MOTOR CO.
Remove the bolt and the fuel tank rear support strap.
- To install, tighten to 55 Nm (41 lb-ft).
Remove the nut and the fuel tank front support strap.
- To install, tighten to 55 Nm (41 lb-ft).
Lower the fuel tank far enough to access the fuel pump electrical connector and disconnect the connector.
Remove the fuel tank from the vehicle.
To install, reverse the removal procedure.