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Removal and Installation

WARNING: This page is about a different car, the 2005 Mercury Montego, 2005 Ford Freestyle, and 2005 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: The evaporative emission 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, possibly causing a fire or explosion if fuel vapor or fuel liquid is present in the area. Failure to follow these instructions may result in personal injury.

    All vehicles 

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .

    3. Five Hundred, Montego 

  3. Remove the rear seat lower cushion.
    • Release the latches and pull upward on the rear lower seat cushion and remove.
      Fig 1: Identifying Lower Seat Cushion Releasing Latch
      G03945904Courtesy of FORD MOTOR CO.

    4. Freestyle 

  4. Position the second row seats to the forward folded position.
  5. Release the 2 load floor support brackets and position the load floor upward.
  6. Position the third row seats into the load floor.
  7. Remove the 4 load floor support-to-floor pan retaining nuts. To install, tighten to 18 Nm (13 lb-ft).
  8. Remove the 2 load floor support brackets.
  9. Position the rear floor carpet and any padding or insulation covering the fuel pump module and fuel level sensor aside.

    10. All vehicles 

  10. Remove the fuel pump module access cover.
  11. Disconnect the fuel vapor control tube assembly valve-to-fuel pump module quick connect coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .

    12. Five Hundred, Montego 

  12. Place a suitable lifting device under the fuel tank.
  13. Remove the RH rear fuel tank strap bolt. To install, tighten to 35 Nm (26 lb-ft).
  14. Partially lower the RH side of the fuel tank.

    15. All vehicles 

  15. Disconnect the fuel vapor control tube assembly valve electrical connector.
  16. Disconnect the vapor tube quick connect coupling-to-fuel vapor control tube assembly valve. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  17. Disconnect the fuel vapor control tube assembly valve-to-vapor tube quick connect coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  18. Release the fuel vapor control tube assembly valve from the retainer clips on the side of the fuel tank.
  19. Remove the fuel vapor control tube assembly valve.
  20. To install, reverse the removal procedure.
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