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Home >> Ford >> 2006 >> Focus ZX5 SE, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 966 (Fuel Tank And Fuel Lines - (Hybrid)) >> Removal And Installation >> Fuel Tank >> Removal

Fuel Tank: Removal

WARNING: This page is about a different car, the 2007 Mercury Mariner and 2007 Ford Escape. 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 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.
WARNING: The fuel in the tank may be pressurized. Remove the fuel tank cap slowly. If a hissing sound is heard, wait until the condition stops before removing the fuel tank filler cap. If these precautions are not followed, fuel may spray and cause personal injury.

All vehicles 

  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. Depower the high voltage traction battery. For additional information, refer to HIGH VOLTAGE TRACTION BATTERY article.
  5. Release the fuel tank filler cap and position aside.
  6. Insert a suitable fuel drain tube into the fuel tank filler pipe until it reaches the fuel tank inlet spout.
    7. Fig 1: Draining Fuel
    GF0025523Courtesy of FORD MOTOR CO.
  7. Attach the fuel storage tanker to the fuel drain tube and remove any residual fuel remaining in the fuel tank filler pipe.

    8. All wheel drive (AWD) vehicles 

  8. Support the exhaust system with a suitable stand, release the 3 rear exhaust hangers and carefully lower the exhaust system to allow enough clearance to remove the fuel tank.
  9. Remove the rear driveshaft. For additional information, refer to DRIVESHAFT article.

    10. All vehicles 

  10. Lift the LH rear seat cushion and position the carpet aside.
  11. Remove the 4 screws and the fuel pump module access cover.
  12. Disconnect the fuel pump module electrical connector.
  13. Disconnect the fuel tank pressure sensor electrical connector.
  14. Disconnect the fuel supply tube and fuel vapor tube quick connect couplings from the fuel delivery module. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
  15. Using a suitable fuel pump lock ring remover, rotate the lock ring counterclockwise and remove.
    16. Fig 2: Fuel Pump Module Lock Ring
    GF0025524Courtesy of FORD MOTOR CO.
    CAUTION: The fuel pump module must be handled carefully to avoid damage to the float arm and filter.
  16. Prior to completely removing the fuel pump, position it aside. Using the special tool and a suitable fuel recovery system, drain the fuel tank.
    17. Fig 3: Draining Fuel
    GF0025525Courtesy of FORD MOTOR CO.
    CAUTION: Some fuel will remain in the fuel pump module after draining the fuel tank. Carefully drain the fuel pump module into a suitable container.
  17. To release the bottom-mounted fuel pump module, reach into the fuel pump module opening and squeeze the retainer tabs on the pump module housing and pull upward.
    18. Fig 4: Fuel Pump Module Retainer Tabs
    GF0025514Courtesy of FORD MOTOR CO.
    NOTE: Be careful that no foreign material falls into tank.
  18. Remove and discard the fuel pump module O-ring seal, making sure the mounting area is clean and free of foreign material.
  19. Detach the fuel vapor hose retainer clip from the fuel tank strap.
  20. Reposition the clamp and disconnect the fuel filler pipe hose from the fuel tank.
  21. Position a suitable lifting device under the fuel tank.
    22. Fig 5: Supporting Fuel Tank
    GF0025515Courtesy of FORD MOTOR CO.
  22. Detach the wiring harness pin-type retainer from the fuel tank strap.
  23. Remove the bolt and the LH fuel tank strap.
  24. Remove the bolt and the RH fuel tank strap.

  25. Partially lower the fuel tank enough to access and disconnect the fuel vapor control tube assembly valve quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
  26. Remove the fuel tank.
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