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Removal and Installation

WARNING: This page is about a different car, the 2006 Mercury Montego, 2006 Ford Freestyle, and 2006 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.
WARNING:
  1. Do not 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 can ignite. Failure to follow these instructions can result in personal injury.
  2. 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.
  3. 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.
  4. 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 vehicles 

  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 PRESSURE RELEASE .
  3. Drain the fuel tank. For additional information, refer to FUEL TANK DRAINING .

    4. All wheel drive vehicles 

  4. Remove the rear driveshaft. For additional information, refer to REMOVAL AND INSTALLATION .

    5. All vehicles 

  5. Remove the muffler. For additional information, refer to REMOVAL AND INSTALLATION .
  6. Disconnect the fuel vapor control tube assembly valve-to-fuel vapor tube quick connect coupling. For additional information, refer to DISCONNECTION .
    7. CAUTION: The fuel tubes and fuel filter may have some fuel remaining within after the fuel system pressure is released. Upon disconnecting the fuel supply tubes or removing the fuel filter, carefully drain the residual fuel into a suitable container.
  7. Disconnect the fuel supply tube-to-fuel filter quick connect coupling. For additional information, refer to DISCONNECTION .
  8. Disconnect the fuel vapor tube-to-fuel vapor control tube assembly valve quick connect coupling. For additional information, refer to DISCONNECTION .
  9. Disconnect the fuel tank wiring harness electrical connector at the rear of the fuel tank.
  10. Release the fuel tank filler pipe hose clamp.
    • To install, tighten to 3 Nm (27 lb-in).
    11. CAUTION: The fuel tank filler pipe may have some residual fuel remaining in it after draining. Upon disconnecting the fuel tank filler pipe hose, carefully drain the residual fuel into a suitable container
  11. Remove the fuel tank filler pipe hose from the fuel tank.
  12. Place a suitable lifting device under the fuel tank.
  13. Remove the 2 front fuel tank strap bolts.
    • To install, tighten to 35 N.m (26 lb-ft).
    14. NOTE: Do not bend the fuel tank straps.
  14. Loosen the 2 rear fuel tank strap bolts and position the 2 fuel tank straps aside.
  15. Lower the fuel tank enough to move forward, clear of the fuel straps then complete the lowering procedure.
  16. To install, reverse the removal procedure.
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