Removal And Installation
WARNING: This page is about a different car, the 2009 Mercury Milan, 2009 Lincoln MKZ, and 2009 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.
All vehicles
- With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING article.
- Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
- Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
- Remove the air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 3.0L (4V) article or INTAKE AIR DISTRIBUTION AND FILTERING - 3.5L article.
- Remove the lower cowl panel. For additional information, refer to the Cowl Panel Grille procedure in FRONT END BODY PANELS article.
- Disconnect the fuel jumper tube-to-fuel tube quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
- Disconnect the vapor jumper tube-to-vapor tube quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
- Remove the 4 nuts and the lower crossover support brace.
- To install, tighten to 76 Nm (56 lb-ft).
- Remove the fuel tank. For additional information, refer to FUEL TANK - FRONT WHEEL DRIVE (FWD) .
- Remove the 2 bolts and position the LH rear parking brake cable assembly aside.
- To install, tighten to 23 Nm (17 lb-ft).
- Disconnect the vapor jumper tube-to-vapor tube quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
- Release the fuel tube bundle retaining clips and remove the fuel and vapor tubes.
- Disconnect the vapor jumper tube-to-Evaporative Emission (EVAP) canister quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
- Release the fuel bundle retaining clips and remove the vapor jumper tube.
- To install, reverse the removal procedure.
3.0L and 3.5L vehicles
NOTE:
The lower cowl panel must be removed to access the fuel and vapor tube quick connect couplings.
All vehicles
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.
NOTE:
The front parking brake cable bolt also retains a stone shield. Position the cable and shield aside.