Ford 5L1Z-9002-AA Fuel Tank Assembly

For the Ford Expedition and Lincoln Navigator, ensure the gauge indicates that the tank is empty or nearly empty before starting the procedure. If the tank must be removed when full, siphon any remaining fuel first. Siphon residual fuel if the vehicle hasn't been driven enough to empty the tank. Relieve the fuel pressure, detach the cable from the negative battery terminal, raise the vehicle securely on jackstands, and remove the fuel tank skid plate mounting bolts to lower the assembly. Remove the fuel tank filler hose and vapor hose from the fuel filler neck and the fuel tank, then disconnect the fuel lines and EVAP vapor lines. Disconnect the electric fuel pump and sending unit electrical connector, using an ohmmeter to check resistance if needed. Place a floor jack under the tank with a block of wood, raise it to support the tank, and remove the bolts retaining the fuel tank mounting straps. Note that Expedition/Navigator models have a large bracket straddling the fuel tank, which must be removed as a complete unit. Lower the tank enough to unplug any vapor lines or wire harness brackets, then slowly lower the jack while steadying the tank to remove it from the vehicle. If replacing the tank or having it cleaned or repaired, follow the appropriate procedures. Installation is the reverse of removal, using clean engine oil as an assembly aid for the fuel filler neck. Ensure the fuel tank heat shields are correctly assembled before reinstalling the tank, and carefully angle the fuel tank filler neck into the filler pipe assembly while lifting the tank into place.

The covered vehicles have plastic fuel tanks.

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

Before beginning the procedure to remove the fuel tank, make sure 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.