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Removal and Installation

WARNING: This page is about a different car, the 2011 Mercury Milan, 2011 Lincoln MKZ, and 2011 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
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: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or 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: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. 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 & LIFTING article.
  2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - FUSION, MILAN & MKZ article.
  3. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING & CABLES -- FUSION, MILAN & MKZ article.
  4. Remove the 4 nuts and 2 heat shields.
  5. Release the pin-type retainer and remove the hybrid fuel tube bundle shield.
    6. NOTE: Some residual fuel may remain in the fuel tubes after releasing the fuel system pressure. When disconnecting or removing any fuel tubes, carefully drain any residual fuel into a suitable container.
  6. Disconnect the fuel jumper tube-to-fuel tube quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - FUSION, MILAN & MKZ article.
  7. Disconnect the vapor jumper tube-to-vapor tube quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - FUSION, MILAN & MKZ article.
  8. If equipped, remove the 6 bolts and the underbody shield.
    Fig 1: Locating Underbody Shield Bolts
    G06271104Courtesy of FORD MOTOR CO.
  9. Remove the 4 nuts and the lower crossover support brace.
    • To install, tighten to 76 Nm (56 lb-ft).
  10. Remove the fuel tank. For additional information, refer to FUEL TANK  in this service information.
    11. NOTE: The LR parking brake cable bolt also retains a stone shield. Position the cable and shield aside.
  11. Remove the bolt, stone shield and position the LR parking brake cable assembly aside.
    • To install, tighten to 23 Nm (17 lb-ft).
  12. Disconnect the vapor jumper tube-to-vapor tube quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - FUSION, MILAN & MKZ article.
  13. Release the 9 fuel tube bundle retaining clips and remove the fuel and vapor tubes.
  14. Disconnect the vapor jumper tube-to-Evaporative Emission (EVAP) canister quick connect coupling and remove the vapor jumper tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - FUSION, MILAN & MKZ article.
  15. To install, reverse the removal procedure.
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