Ford 1L5Z-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. This procedure requires a special fuel line disconnect tool which is available at most auto part stores. Some models may be equipped with a fuel line disconnect tool which is installed on the vehicle about ten inches behind the fuel filter. 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. Disconnect the cable from the negative terminal of the battery. Raise the vehicle and support it securely on jackstands. On 4WD models, remove the shield, skid plate and the front retaining strap. Loosen the hose clamps and disconnect the fuel filler and vent hose at the fuel tank. Remove the fuel tank ground strap. On models through 2000, disconnect the fuel pump electrical connector located on the left frame rail. On 2001 and later models, you can access and disconnect the fuel pump/sending unit electrical connector only when the tank has been lowered from the vehicle. Support the fuel tank with a floor jack. Position a piece of wood between the jack head and the fuel tank to protect the tank. Remove the bolt from the rear retaining strap and pivot the strap down until it is hanging out of the way. Remove the bolts securing the front of the fuel tank, then move the tank rearward until it clears the front retaining bracket. Lower the tank enough to disconnect the fuel line connectors from the fuel pump and vapor valve. The fuel feed and return lines and the vapor return line are three different diameters, so reattachment is simplified. If you have any doubts, however, clearly label the three lines and the fittings. Be sure to plug the hoses to prevent leakage and contamination of the fuel system. On early models, disconnect the fuel pump and fuel gauge sending unit connectors. Remove the tank from the vehicle. Installation is the reverse of removal. The manufacturer recommends that new tank retaining strap bolts be used. Remove and 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 hose back onto the fuel tank.

The fuel tanks in these vehicles are constructed from non corrosive steel or polyethylene plastic. Unfortunately, there are no reliable repair procedures to correct leaks or damage on polyethylene plastic fuel tanks, hence, replacement is the only approved service. Any repairs on steel fuel tanks or filler necks should be undertaken by a professional with experience in this critical and potentially dangerous work. If the fuel tank is removed from the vehicle, it should be kept away from areas where sparks or open flames could ignite the fumes emanating from the tank. Extra caution should be exercised inside garages where a natural gas-type appliance is located, as the pilot light could trigger an explosion. In instances where the fuel tank is steam-cleaned or serviced in any other way, the vapor valve assembly should be replaced. It is also important to replace all grommets and seals to prevent possible leakage.