Mercury 6W1Z-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. Warning: DO NOT start the siphoning action by mouth! Use a siphoning kit, available at most auto parts stores. 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 filler neck bracket bolts securing the fuel filler neck and the fuel tank filler pipe retainer and slide the assembly from the vehicle. Disconnect the fuel lines and vapor lines. Remove 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 or nuts from the front ends of the fuel tank straps. The straps are hinged at the other end so you can swing them out of the way. 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. Remove and install the fuel pump/sending unit. Installation is the reverse of removal. SAE 10W-40 engine oil can be used as an assembly aid when pushing the fuel filler neck back into the tank.

A professional with the proper training should perform these repairs.

The fuel tank should not be placed in an area where sparks or open flames could ignite the fumes coming out of the tank.

It's advisable to siphon out residual fuel before removing the tank. This precaution ensures safer tank removal. Remember, never use your mouth to start the siphoning process; always use a siphoning kit available at most auto parts stores.