Fuel Tank and Filler Pipe - 4.0L SOHC Early Build: Notes
WARNING: This page is about a different car, the 2004 Mercury Mountaineer and 2004 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:
The evaporative emissions system contains fuel vapor. Although not present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery ground to minimize the possibility of an electrical spark occurring, possibly causing fire or explosion if fuel vapor or liquid fuel are present in the area. Failure to follow these instructions can result in personal injury.
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 & LIFTING .
- Disconnect the battery ground cable. For additional information, refer to BATTERY DISCONNECT .
- When removing the fuel tank, it will be necessary to release the fuel system pressure. For additional information, refer to FUEL SYSTEM PRESSURE RELEASE .
- When removing the fuel tank, it will be necessary to remove the driveshaft. For additional information, refer to DRIVELINE SYSTEM .
- When removing the fuel tank, it will be necessary to release the fuel tank fill hose clamp and disconnect the fuel filler hose from the fuel filler pipe assembly.
- When removing the fuel tank, it will be necessary to use the special tool and siphon the fuel through the lower fuel filler hose into a suitable container.
- If equipped, remove the fuel tank skid plate.
- Remove the three bolts at the outboard frame rail.
- Remove the two nuts on the inboard side of fuel tank to the No. 3a and No. 3b frame crossmembers.
- Remove the skid plate.
- If equipped, remove the transfer case skid plate by removing the four bolts from the outer frame rail (two per side).
- Remove the components in the order indicated in the following illustration and table. To remove individual components, only carry out the listed steps.COMPONENTS SPECIFICATION
Component Steps Fuel filler pipe 1-10 Fuel tank 4, 6-8, 11-19 Fuel pump 4, 6-8, 10-24 - To install, reverse the removal procedure.
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.