Ford 5L1Z-9002-AA Fuel Tank Assembly

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Don't begin this procedure until the gauge indicates that the tank is empty or nearly empty. If the tank must be removed when it's full (for example, if the fuel pump malfunctions), siphon any remaining fuel from the tank prior to removal. Unless the vehicle has been driven far enough to completely empty the tank, it's a good idea to siphon the residual fuel out before removing the tank from the vehicle. Relieve the fuel pressure. Detach the cable from the negative terminal of the battery. Raise the vehicle and support it securely on jackstands. Remove the fuel tank skid plate mounting bolts and lower the assembly. Remove the fuel tank filler hose and vapor hose from the fuel filler neck and the fuel tank and slide the assembly from the vehicle. Disconnect the fuel lines and EVAP vapor lines. Disconnect the electric fuel pump and sending unit electrical connector with a screwdriver. Place a floor jack under the tank and position a block of wood between the jack pad and the tank. Raise the jack until it's supporting the tank. Remove the bolts that retain the fuel tank mounting straps. The straps are hinged at the other end so you can swing them out of the way. Expedition/Navigator models use a large bracket that straddles the entire fuel tank. The mounting bolts and bracket must be removed as a complete unit before the fuel tank can be lowered. The assembly will be lowered with the fuel tank because it will be positioned between the fuel tank and the lifting jack. Lower the tank far enough to unplug any vapor lines or wire harness brackets that may be difficult to reach when the fuel tank is in the vehicle. Slowly lower the jack while steadying the tank. Remove the tank from the vehicle. If you're replacing the tank, or having it cleaned or repaired. Install the fuel pump or sending unit. Installation is the reverse of removal. Clean engine oil can be used as an assembly aid when pushing the fuel filler neck back into the tank. Make sure the fuel tank heat shields are assembled correctly onto the fuel tank before reinstalling the tank in the vehicle. Carefully angle the fuel tank filler neck into the filler pipe assembly and lift the tank into place.

After disconnecting the fuel lines and EVAP vapor lines, you should disconnect the electric fuel pump and sending unit electrical connector using a screwdriver.

It is especially crucial to avoid placing the fuel tank near sparks or open flames in garages with gas-type appliances.

The covered vehicles have plastic fuel tanks.