Removal and Installation

WARNING: This page is about a different car, the 2006 Mercury Grand Marquis and 2006 Ford Crown Victoria. 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, resulting in possible 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: 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.

WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning the air suspension switch located in the luggage compartment on the LH side to the OFF position. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations.

WARNING: If equipped with fire suppression system, depower the system. For important safety warnings and procedures, refer to FIRE SUPPRESSION SYSTEM .

Release the fuel system pressure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
Remove the fuel tank filler pipe. For additional information, refer to FUEL TANK FILLER PIPE .
Drain the fuel tank. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
Disconnect the fuel pump connector located above the No. 4 crossmember.

Fig 1: Disconnecting Fuel Pump Connector Located Above No 4 Crossmember
Courtesy of FORD MOTOR CO.
Disconnect the fuel supply tube spring lock coupling at the fuel pump module. For additional information, refer FUEL SYSTEM-GENERAL INFORMATION .
Disconnect the vapor tube quick connect coupling to fuel vapor control tube assembly valve located on the RH side of fuel tank. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .

Fig 2: Disconnecting Fuel Supply Tube Spring Lock Coupling To Fuel Vapor Control Tube Assembly Valve
Courtesy of FORD MOTOR CO.
Disconnect the vapor tube quick connect coupling-to-fuel vapor control tube assembly valve nipple. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .

Fig 3: Disconnecting Vapor Tube Quick Connect Coupling-To-Fuel Vapor Control Tube Assembly Valve Nipple
Courtesy of FORD MOTOR CO.
Position a suitable lifting device under the fuel tank.

NOTE: Discard old retaining nuts. Do not reuse.

Fig 4: Removing Fuel Tank Strap Retaining Nuts

Courtesy of FORD MOTOR CO.

Remove the fuel tank strap retaining nuts and position the straps away from the fuel tank.
Lower the fuel tank.

NOTE: The fuel tank mounting studs are a break-off style. After installing the new fuel tank mounting studs, break-off the excess length at the recess in the studs.

Fig 5: Removing Original Fuel Tank Strap Mounting Studs

Courtesy of FORD MOTOR CO.

Remove and discard the original fuel tank strap mounting studs and replace with new studs and nuts.

NOTE: If a new tank is being installed, the fuel vapor control tube assembly valve can be reused on the new tank.

To install, reverse the removal procedure.

WARNING: If equipped with fire suppression system, repower the system. For important safety warnings and procedures, refer to FIRE SUPPRESSION SYSTEM .

If equipped with fire suppression system, repower the system.