Ford YC3Z-9002-EB Fuel Tank Assembly

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Before starting the procedure, ensure the gauge indicates that the tank is empty or nearly empty. If removal is necessary when the tank is full, siphon any remaining fuel into an approved container. First, relieve the fuel system pressure based on the vehicle type. Remove the fuel filler cap to relieve tank pressure, then disconnect the negative battery cable. If the tank is full, siphon the fuel. Raise the vehicle securely on jackstands. The fuel tank's location may vary depending on the model. Remove the fuel tank skid plate mounting bolts and lower the assembly. Detach the fuel tank filler hose and vapor hose from the filler neck and tank, and separate the splash panel from the fenderwell. Use a floor jack to support the tank, then disconnect the fuel lines and EVAP vapor lines, ensuring to disconnect the fuel tank pressure sensor if equipped. Disconnect the electric fuel pump and sending unit electrical connector, which may require lowering the tank slightly for access. Remove the bolts retaining the fuel tank straps, and for diesel auxiliary tanks, remove the cover strap bolts and drop the tank and straps as a complete assembly. Lower the tank enough to unplug any vapor lines or wire harness brackets that are hard to reach. Slowly lower the jack while steadying the tank and remove it from the vehicle. If replacing the tank or having it cleaned or repaired, follow the appropriate procedures. To install, reverse the removal steps, using clean engine oil as an assembly aid for the fuel filler neck. Ensure any heat shields are correctly assembled onto the tank before reinstalling it, and carefully angle the filler neck into the filler pipe assembly while lifting the tank into place.

Repairs to the steel fuel tank or filler pipe should be performed by a professional with the proper training to carry out this critical and potentially dangerous job. Even after cleaning and flushing, explosive fumes can remain and could explode during repair of the tank.