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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 2191 (Fuel Tank & Fuel Lines - (Except Hybrid)) >> Removal And Installation >> Fuel Tank Filler Pipe

Fuel Tank Filler Pipe

WARNING: This page is about a different car, the 2008 Mercury Mariner and 2008 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
Special Tools

Illustration Tool Name Tool Number
GF0004198Courtesy of FORD MOTOR CO.
 Fuel Drain Hose 310-102
GF0004199Courtesy of FORD MOTOR CO.
 Fuel Storage Tanker 164-R3202 or equivalent
WARNING: Do not smoke, carry lighted tobacco or have an 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 serious 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 component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.
WARNING: Remove the fuel filler cap slowly. The fuel system may be under pressure. If the fuel filler cap is venting vapor or if you hear a hissing sound, wait until it stops before completely removing the fuel filler cap. Otherwise, fuel may spray out. Failure to follow these instructions may result in serious personal injury.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING article.
  2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
  3. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
  4. Release the fuel tank filler cap and position aside.
  5. Insert the special tool into the fuel tank filler pipe until it opens the fuel tank level shutoff valve located at the inlet of the fuel tank.
    6. Fig 1: Identifying Special Tool (310-102)
    GF0042460Courtesy of FORD MOTOR CO.
    NOTE: Due to the internal design of the fuel tank components, slow fuel drainage may occur.
  6. Using the special tools, drain as much fuel as possible from the fuel tank and filler pipe, lowering the fuel level below the inlet of the fuel tank.
  7. Remove the 4 screws and the fuel pump (FP) module access cover.
    8. NOTE: Clean the FP module connection, couplings, mounting flange and the immediate surrounding area of any dirt or foreign material.
  8. Disconnect the FP module electrical connector.
    9. NOTE: Place absorbent toweling in the immediate surrounding area in case of fuel spills.
  9. Disconnect the fuel supply tube and fuel vapor tube-to-FP module quick connect couplings. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
    10. NOTE: Carefully remove the FP module lock ring and verify that enough fuel has been drained to avoid spillage.
  10. Using a suitable FP lock ring remover, rotate the lock ring counterclockwise and remove.
    11. NOTE: A partial fuel tank drain is required to lower the fuel level below the fuel tank inlet and avoid fuel spillage upon removal of the fuel tank filler pipe hose and clamp.
  11. Position the FP module aside and, using the fuel storage tanker, drain enough fuel so the fuel level in the fuel tank is below the fuel tank inlet.
  12. Remove the 2 fuel tank filler pipe flange screws and the dust cover.
    • To install, tighten to 3 Nm (27 lb-in).
  13. Remove the LH rear wheel and tire. For additional information, refer to SUSPENSION SYSTEM - GENERAL INFORMATION article.
  14. Remove the 3 rivets and the fuel tank filler pipe shield.
  15. Remove the fuel tank filler pipe bracket bolt.
    • To install, tighten to 10 Nm (89 lb-in).
  16. Disconnect the fuel vapor tube-to-fuel tank filler pipe quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
  17. Detach the 2 fuel vapor tube retaining clips.
  18. Disconnect the fuel tank filler pipe vent tube from the dust separator.
  19. Release the clamp and remove the fuel tank filler pipe hose from the fuel tank.
    • To install, tighten to 4 Nm (35 lb-in).
  20. Remove the fuel tank filler pipe.
  21. To install, reverse the removal procedure.
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