Ford 4L5Z-9002-BA Fuel Tank Assembly

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The following procedure is much easier to perform if the fuel tank is empty. Some tanks have a drain plug for this purpose. If the tank does not have a drain plug, siphon the gasoline into an approved gasoline container. Remove the fuel tank filler cap to relieve fuel tank pressure. Relieve the fuel system pressure. Detach the negative cable from the battery. If the tank still has fuel in it, siphon it into an approved gasoline container. Warning: Don't start the siphoning action by mouth/ Use a siphoning kit, available at most auto parts stores. Raise the vehicle and place it securely on jack stands. Remove the heat shield, skid plate (If equipped) and the front retaining strap. Support the fuel tank with a floor jack or jack stands. Position a piece of wood between the jack head and the fuel tank to protect the tank. On 2010 and earlier models, remove the bolt from the rear retaining strap and pivot the strap down until it is hanging out of the way. Loosen the screw clamps at the fill pipe and the vent pipe. Disconnect the pipes at the tank. Lower the tank enough to disconnect all the vapor valve, fuel line and electrical connectors from the sender unit, vapor vapor and fuel pump module (as equipped).Note: To simplify installation, clearly label the hoses/ lines and fittings. Plug the hoses/lines to prevent leakage and contamination of the fuel system. Note: On 2011 models, the fuel pump module cover must be removed to access some of the connectors. Disconnect any remaining fuel pump, fuel gauge sending unit, or Fuel Tank Pressure (FTP) sensor connectors (as equipped) at the rear of the fuel tank. Remove the tank from the vehicle. Warning: Store the tank in a safe place, away from sparks and open flames. Installation is the reverse of removal.The manufacturer recommends that new tank retaining strap bolts be used. On 2011 models, tighten the fuel pump module cover nuts to 80 in-lbs.

Whenever the fuel tank is steam-cleaned or otherwise serviced, the vapor valve assembly should be replaced. All grommets and seals must be replaced to prevent possible leakage.