Fuel Tank and Filler Pipe: Material

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, possibly causing a fire or explosion if fuel vapor or liquid fuel are present in the area. Failure to follow these instructions may result in personal injury.
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 may result in personal injury.
1. Disconnect the battery ground cable. For additional information, refer to BATTERY & CHARGING SYSTEM .
2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM PRESSURE RELEASE .
3. With the vehicle in NEUTRAL, position on a hoist.
4. Remove the driveshaft. For additional information, refer to DRIVELINE SYSTEM .
5. If equipped, remove the fuel tank skid plate.
6. Remove the components in the order indicated in the following illustration and table. To remove individual components, only carry out the listed steps.
   Fig 2: Component Removal Steps Table

   Courtesy of FORD MOTOR CO.
7. To install, reverse the removal procedure.
   Fig 3: Removal Sequence Of Fuel Tank And Filler Pipe

   Courtesy of FORD MOTOR CO.
   Fig 4: Removal Sequence Of Fuel Tank And Filler Pipe Table

   Courtesy of FORD MOTOR CO.

Item 4: Push Connect Fitting Removal Note 

1. Disconnect the safety clip.
   Fig 5: Disconnecting Safety Clip

   Courtesy of FORD MOTOR CO.
2. Install the special tool and push it into the fitting.
   Fig 6: Installing Special Tool And Push It Into The Fitting

   Courtesy of FORD MOTOR CO.
3. Separate the fittings.
   • Inspect for damage.
   • Clean the fittings.
     Fig 7: Separating Fittings

     Courtesy of FORD MOTOR CO.

Item 6: Clamp Removal Note 

1. Disconnect the fuel filler hose from the fuel filler intermediate pipe.
   Fig 8: Disconnecting Fuel Filler Hose From Fuel Filler Intermediate Pipe

   Courtesy of FORD MOTOR CO.
2. Using the special tool, siphon the fuel through the fuel filler hose.
   Fig 9: Siphon Fuel Through Fuel Filler Hose By Using Special Tool

   Courtesy of FORD MOTOR CO.

Item 7: Fuel Tank Removal Note 

1. Use a suitable jack to support the fuel tank.
   Fig 10: Supporting Fuel Tank By Suitable Jack

   Courtesy of FORD MOTOR CO.

Item 14: Fuel Filler Pipe Removal Note 

1. Slightly lower the fuel tank.

Item 18: Quick Connect Fitting Removal Note 

1. Unclip the tab.
   Fig 11: Unclipping Tab

   Courtesy of FORD MOTOR CO.
2. Depress the tabs and press the clip downward.
   Fig 12: Depressing Tabs And Press Clip Downward

   Courtesy of FORD MOTOR CO.
3. Separate the fittings.
   Fig 13: Separating Fittings

   Courtesy of FORD MOTOR CO.

Item 19: Fuel Pump Lock Ring Removal Note 

1. Install the special tool.
   Fig 14: Installing Special Tool In Fuel Pump Lock Ring

   Courtesy of FORD MOTOR CO.

Item 4: Push Connect Fitting Installation Note 

NOTE: Lubricate the fuel fitting with clean engine oil.
1. Align the fuel line fitting and press together until a click is heard.
   • Pull on the fitting to make sure it is fully engaged, then install the safety clip.
     Fig 15: Installing Safety Clip

     Courtesy of FORD MOTOR CO.