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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.
  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. Disconnect the evaporative emission (EVAP) tube-to-throttle body adapter quick connect coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  5. Disconnect the fuel supply tube-to-fuel rail quick connect coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  6. Remove the EVAP tube and fuel supply tube from the engine mounted fuel tube bundle retainer clip.
  7. Remove the 2 nuts and the upper cowl heat shield.
    • To install, tighten to 9 Nm (80 lb-in).
      Fig 1: Locating Upper Cowl Heat Shield Nuts
      G04684207Courtesy of FORD MOTOR CO.
  8. Remove the 2 nuts and the lower cowl shield.
    • To install, tighten to 9 Nm (80 lb-in).
      Fig 2: Locating Lower Cowl Shield Nuts
      G04684208Courtesy of FORD MOTOR CO.
  9. Disconnect the EVAP tube-to-purge valve quick connect coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  10. Disconnect the EVAP test port-to-purge valve quick connect coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  11. Disconnect the EVAP test port tube-to-EVAP tube quick connect coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  12. Remove the EVAP tube and the EVAP test port from the 2 cowl tube bundle upper retainer clips and remove the tubes from the vehicle.
    Fig 3: Locating Cowl Tube Bundle Upper Retainer Clips
    G04684209Courtesy of FORD MOTOR CO.
  13. Remove the fuel supply and EVAP tube from the 3 cowl tube bundle lower retaining clips.
    Fig 4: Locating Cowl Tube Bundle Lower Retaining Clips
    G04684210Courtesy of FORD MOTOR CO.
  14. Remove the 4 nuts and the lower crossover support brace.
    • To install, tighten to 76 Nm (56 lb-ft).
      Fig 5: Locating Lower Crossover Support Brace Nuts
      G04684211Courtesy of FORD MOTOR CO.
  15. Remove the fuel tank. For additional information, refer to FUEL TANK .
  16. Remove the 3 bolts and position the LH rear parking brake cable assembly aside.
    • To install, tighten to 23 Nm (17 lb-ft).
      Fig 6: Locating LH Rear Parking Brake Cable Assembly Bolts
      G04684212Courtesy of FORD MOTOR CO.
  17. Disconnect the EVAP tube-to-EVAP hose quick connect coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  18. Remove the fuel supply and EVAP tube from the 4 floorpan tube bundle retainer clips and remove the tubes from the vehicle.
    Fig 7: Locating Floorpan Tube Bundle Retainer Clips
    G04684213Courtesy of FORD MOTOR CO.
  19. Remove the 3 fuel vapor control tube assembly valve heat shield nuts and heat shield.
    • To install, tighten to 10 Nm (89 lb-in).
  20. Remove the EVAP tube from the bundle clip located on the rear upper floor pan.
    Fig 8: Locating EVAP Tube From Bundle Clip
    G04684214Courtesy of FORD MOTOR CO.
  21. Disconnect the EVAP tube-to-EVAP canister quick connect coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  22. Remove the EVAP tube from the 2 bundle retainer clips located above the fuel tank and remove the tube from the vehicle.
    Fig 9: Locating Bundle Retainer Clips
    G04684215Courtesy of FORD MOTOR CO.
  23. Disconnect the fuel vapor control tube assembly valve electrical connector.
  24. Disconnect the fuel vapor control tube assembly valve-to-EVAP canister quick connect coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  25. Release the 2 retainer clips and remove the fuel vapor control tube assembly valve.
  26. To install, reverse the removal procedure.
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