Removal and Installation

WARNING: This page is about a different car, the 2006 Mercury Milan, 2006 Lincoln Zephyr, and 2006 Ford Fusion. 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: 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

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
Release the fuel system pressure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Drain the fuel tank. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
Release the clamp and disconnect the fuel tank filler pipe hose from the fuel tank.
Disconnect the fuel vapor control tube assembly valve quick connect coupling from the fuel tank. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .

Fig 1: Locating Valve Quick Connect Coupling From Fuel Tank
Courtesy of FORD MOTOR CO.
Support the exhaust system with suitable jack stands.
Remove the 2 nuts and the catalytic converter from the exhaust flexible pipe.
- To install, tighten to 40 Nm (30 lb-ft).
- Discard the catalytic converter flange gasket.
  
  Fig 2: Locating Catalytic Converter Nuts
  Courtesy of FORD MOTOR CO.

Vehicles with 2.3L engine

With the aid of an assistant, release the 4 exhaust hangers and remove the exhaust system.

Fig 3: Locating Exhaust Hangers
Courtesy of FORD MOTOR CO.

Vehicles with 3.0L engine

With the aid of an assistant, release the 5 exhaust hangers and remove the exhaust system.

Fig 4: Locating Exhaust Hangers
Courtesy of FORD MOTOR CO.

All vehicles

Remove the 4 nuts, 2 clips and 2 pin-type retainers from the fuel tank heat shield.
- Remove the fuel tank heat shield.
  
  Fig 5: Locating Fuel Tank Heat Shield
  Courtesy of FORD MOTOR CO.
Install a suitable lifting device below the fuel tank.
Remove the 4 bolts and the 2 fuel tank mounting straps.
- To install, tighten to 47 Nm (35 lb-ft).
Carefully lower the fuel tank.
To install, reverse the removal procedure.
- Install a new catalytic converter flange gasket.