Material
| Item | Specification | Fill Capacity |
|---|
| Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil a XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent | WSS-M2C930-A | |
| Motorcraft SAE 5W-30 Premium Synthetic Blend Motor Oil b XO-5W30-QSP (US); Motorcraft SAE 5W-30 Super Premium Motor Oil CXO-5W30-LSP12 (Canada); or equivalent | WSS-M2C929-A | |
GENERAL SPECIFICATIONS
TORQUE SPECIFICATIONS
| Description | Nm |
|---|
| Fuel tank filler pipe clamp | 3 |
The fuel system consists of
- fuel and vapor tubes.
- fuel filter.
- fuel pump (FP).
- fuel tank filler pipe assembly.
- fuel tank.
- fuel rail.
- fuel injectors.
- inertia fuel shutoff (IFS) switch.
The vehicle is equipped with electronic multi-port fuel injection that is supplied by an electronic returnless fuel system. The PCM receives pressure information from a fuel pressure sensor mounted on the fuel rail. The PCM is able to maintain constant fuel pressure by varying the FP output. This is accomplished by increasing or decreasing voltage supplied to the FP. The returnless fuel system offers improved economy, lower fuel temperatures and decreased fuel vapor in the fuel tank.
Special Tools Illustration Tool Name Tool Number Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool
Scheme 9
Principles of Operation
The fuel tank filler pipe assembly is used to refuel the vehicle. The fuel tank inlet check valve prevents spitback of fuel during and after refueling. The fuel tank stores the fuel. The fuel tank contains a Fuel Pump (FP) module. The FP module consists of a fuel level sender and a FP. The fuel level sender sends a signal to the fuel gauge informing the driver of how much fuel is in the fuel tank. The FP provides fuel to the fuel tubes which supply the fuel rail.
During refueling, the fuel tank vents to the atmosphere through the vent and filler pipes, on vehicles without On-Board Refueling Vapor Recovery (ORVR) systems. In vehicles equipped with ORVR the fuel tank and filler pipe are designed so that when the vehicle is being refueled, fuel vapors in the fuel tank travel to the Evaporative Emission (EVAP) canister, which absorbs the fuel vapors and vents the pressure from the fuel tank during refueling.
Inspection and Verification
| WARNING | Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. |
| WARNING | Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. |
| WARNING | When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. |
| WARNING | Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. |
Note. Do not use incandescent lights when inspecting the fuel system. Use only flourescent or LED lighting.
- Verify the customer concern by refueling the vehicle and observe the fuel fill rate.
- Inspect to determine if any of the following mechanical concerns apply. VISUAL INSPECTION CHART Mechanical Bent, kinked or damaged fuel tank filler pipe Bent, kinked or damaged fuel tank filler pipe vent tube (if equipped) Incorrect routing of the fuel tank filler pipe Incorrect routing of the fuel tank filler pipe vent tube (if equipped) Incorrect position of fuel tank filler pipe clamps Incorrect position of fuel tank filler pipe vent tube clamps (if equipped) Fuel tank mounted vapor tubes bent or damaged Evaporative Emission (EVAP) system tubes or hoses bent or damaged Accident damage to the fuel tank Accident damage to the vehicle effecting the fuel tank filler pipe-to-body connection Unauthorized modifications and/or alterations to the vehicle EVAP system fresh air hose plugged (dirt, spider webbing)
- If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
- If the cause is not visually evident, connect the scan tool to the Data Link Connector (DLC).
- If the scan tool does not communicate with the VCM: check the VCM connection to the vehicle. check the scan tool connection to the VCM. refer to «MODULE COMMUNICATIONS NETWORK»(/ford/explorer-sport-trac/ii-2006-2010/remont/communication-devices/#module-communications-network) article, No Power To The Scan Tool, to diagnose no power to the scan tool.
- If the scan tool does not communicate with the vehicle: verify the ignition key is in the ON position. verify the scan tool operation with a known good vehicle. refer to «MODULE COMMUNICATIONS NETWORK»(/ford/explorer-sport-trac/ii-2006-2010/remont/communication-devices/#module-communications-network) article to diagnose no response from the PCM.
- Carry out the network test. If the scan tool responds with no communication for one or more modules, refer to «MODULE COMMUNICATIONS NETWORK»(/ford/explorer-sport-trac/ii-2006-2010/remont/communication-devices/#module-communications-network) article. If the network test passes, retrieve and record continuous memory DTCs.
- Clear the continuous DTCs and carry out the self-test diagnostics for the EVAP system using the scan tool.
- If the DTCs retrieved are related to the concern, go to Evaporative Emission System DTC Chart. For PCM-related DTCs, refer to the «Introduction - Gasoline Engines»(/ford/explorer-sport-trac/ii-2006-2010/remont/testing-diagnostics/#engine-controls-introduction-except-diesel-hybrid) article. For all other DTCs, refer to «MULTIFUNCTION ELECTRONIC MODULES»(/ford/explorer-sport-trac/ii-2006-2010/remont/communication-devices/#multifunction-electronic-modules) article.
- If no DTCs related to the concern are retrieved, go to «Symptom Chart»(/ford/explorer-sport-trac/ii-2006-2010/remont/fuel-system/#fuel-system-general-information) .
Evaporative Emission System DTC Chart
| DTC | Description | Action |
|---|
| P0446 | Evaporative Emission System Vent Control Circuit | Go to Pinpoint Test A . |
| P0451 | Evaporative Emission System Pressure Sensor/Switch Range/Performance | Go to Pinpoint Test A . |
| P0452 | Evaporative Emission System Pressure Sensor/Switch Low | Go to Pinpoint Test A . |
| P0453 | Evaporative Emission System Pressure Sensor/Switch High | Go to Pinpoint Test A . |
| P0454 | Evaporative Emission System Pressure Sensor/Switch Intermittent | Go to Pinpoint Test A . |
| P1443 | Evaporative Emission System Control Valve (Low/No Flow) | Go to Pinpoint Test A . |
| P1450 | Unable to Bleed up Fuel Tank Vacuum | Go to Pinpoint Test A . |
| P1451 | Evaporative Emission System Vent Control Circuit | Go to Pinpoint Test A . |
| P260F | Emission System Monitoring Processor Performance | Go to Pinpoint Test A . |
Symptom Chart
| Condition | Possible Sources | Action |
|---|
| Slow to fill | Fuel tank filler pipe Fuel tank filler pipe vent tube, if equipped Evaporative Emission (EVAP) system Fuel tank inlet check valve (part of the fuel tank) Fuel level vent valve, if equipped (part of the Fuel Pump (FP) module) | Go to Pinpoint Test A . |
| All other fuel system concerns | Fuel system components | REFER to the Introduction - Gasoline Engines article. |
Normal Operation
Under normal operation, fuel should flow at a steady rate through the fuel tank filler pipe into the fuel tank. As fuel enters the fuel tank air is vented through the filler pipe or the On-Board Refueling Vapor Recovery (ORVR) system.
- Fuel tank filler pipe vent tube, if equipped
- Fuel tank filler pipe
- Evaporative Emission (EVAP) system
- Fuel tank inlet check valve (part of the fuel tank)
- Fuel level vent valve, if equipped (part of the Fuel Pump (FP) module)
PINPOINT TEST A: SLOW TO FILL
- A1 CARRY OUT INSPECTION AND VERIFICATION Carry out inspection and verification. Was the cause of the concern found? YES : REPAIR or INSTALL new components to correct the concern. NO : Go to A2 .
- A2 CHECK THE SYSTEM FOR ANY EVAP DTCs Connect the scan tool. Check the system for any of the following EVAP DTCs: P0446, P0451, P0452, P0453, P0454, P1443, P1450, P1451 and P260F. Are any of these DTCs present? YES : REFER to «Introduction - Gasoline Engines»(/ford/explorer-sport-trac/ii-2006-2010/remont/testing-diagnostics/#engine-controls-introduction-except-diesel-hybrid) article to diagnosis the EVAP system. NO : Go to A3 .
- A3 MONITOR THE FTP WHILE FILLING THE FUEL TANK Monitor the FTP reference value while filling the fuel tank. Refer to the Reference Valves in the «Introduction - Gasoline Engines»(/ford/explorer-sport-trac/ii-2006-2010/remont/testing-diagnostics/#engine-controls-introduction-except-diesel-hybrid) article. Is FTP within specification? YES : Go to A5 . NO : Go to A4 .
- A4 MONITOR THE FTP WHILE FILLING THE FUEL TANK WITH THE EVAP SYSTEM DISCONNECTED Disconnect the fuel tank-to-EVAP canister quick connect coupling at the EVAP canister. Monitor the FTP reference value while filling the fuel tank. Refer to «Introduction - Gasoline Engines»(/ford/explorer-sport-trac/ii-2006-2010/remont/testing-diagnostics/#engine-controls-introduction-except-diesel-hybrid) article. Is FTP within specification? YES : INSPECT the EVAP system for blockage or restrictions. REPAIR the blockage or restriction. If the blockage or restriction cannot be repaired, INSTALL new EVAP system components. NO : Go to A5 .
- A5 CHECK THE FUEL TANK FILLER PIPE ASSEMBLY FOR BLOCKAGE OR RESTRICTION Remove the fuel tank filler pipe assembly. Refer to «FUEL TANK AND LINES»(/ford/explorer-sport-trac/ii-2006-2010/remont/fuel-system/#fuel-tank-and-fuel-lines) article. Inspect the fuel tank filler pipe and fuel tank filler pipe vent tube (if equipped) for a blockage or restriction. Is the fuel tank filler pipe or fuel tank filler pipe vent tube (if equipped) blocked or restricted? YES : If possible, REPAIR the blockage or restriction. If the blockage or restriction cannot be repaired, INSTALL a new fuel tank filler pipe or fuel tank filler pipe vent tube. NO : Go to A6 .
- A6 CHECK THE FUEL TANK INLET CHECK VALVE Inspect the fuel tank inlet check valve for restriction or sticking. Is the fuel tank inlet check valve restricted or sticking? YES : If possible, REPAIR the restrictions. If the restriction cannot be repaired, INSTALL a new fuel tank. REFER to «FUEL TANK AND LINES»(/ford/explorer-sport-trac/ii-2006-2010/remont/fuel-system/#fuel-tank-and-fuel-lines) article. NO : Go to A7 .
- A7 CHECK TO MAKE SURE THAT THE FUEL LEVEL VENT VALVE IS FUNCTIONING CORRECTLY NOTE: The fuel level vent valve, if equipped, is part of the FP module. Remove the FP module. Refer to «FUEL TANK AND LINES»(/ford/explorer-sport-trac/ii-2006-2010/remont/fuel-system/#fuel-tank-and-fuel-lines) article. Inspect the fuel level vent valve for foreign material at the bottom drain hole. Invert the FP Watch for a movement and a click noise. Was a movement/click noise witnessed? YES : Fuel level vent valve is OK. RETEST the system for normal operation. NO : INSTALL a new FP module. REFER to «FUEL TANK AND LINES»(/ford/explorer-sport-trac/ii-2006-2010/remont/fuel-system/#fuel-tank-and-fuel-lines) article.
Fuel System Pressure Release
| WARNING | Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. |
| WARNING | Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. |
- Remove the front passenger door frame scuff plate.
- Remove the front passenger side interior kick panel.
- Disconnect the inertia fuel shutoff (IFS) switch electrical connector.
- Start the engine and allow it to idle until it stalls.
- After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail pressure has been released.
- Turn the ignition switch to the OFF position.
- When the fuel system service is complete, reconnect the IFS switch electrical connector.
- Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine.
- Start the vehicle and check the fuel system for leaks.
- Install the front passenger side interior kick panel.
- Install the front passenger door frame scuff plate.
Fuel System Pressure Test
Special Tools Illustration Tool Name Tool Number Fuel Pressure Test Kit 310-D009 (D95L-7211-A)
| WARNING | Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. |
| WARNING | Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. |
| WARNING | Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. |
| WARNING | When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. |
- Release the fuel system pressure. For additional information, refer to «Fuel System Pressure Release»(/ford/explorer-sport-trac/ii-2006-2010/remont/fuel-system/#fuel-system-general-information__fuel-system-pressure-release) .
- Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/explorer-sport-trac/ii-2006-2010/remont/body-electrical/#battery-mounting-and-cables) article.
- Disconnect the fuel supply tube-to-fuel rail spring lock coupling. For additional information, refer to «Spring Lock Couplings»(/ford/explorer-sport-trac/ii-2006-2010/remont/fuel-system/#fuel-system-general-information__spring-lock-couplings) .
- Install the special tool in line between the fuel supply tube and fuel rail.
- Connect the IFS switch electrical connector.
- Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/explorer-sport-trac/ii-2006-2010/remont/body-electrical/#battery-mounting-and-cables) article.
- Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine.
- Test the fuel system pressure to make sure it is within the specified range. For additional information, refer to «SPECIFICATIONS»(/ford/explorer-sport-trac/ii-2006-2010/remont/fuel-system/#fuel-system-general-information) .
- Upon completion of the fuel system pressure test, open the drain valve on the special tool and relieve the fuel system pressure.
Fuel Tank Draining
Special Tools Illustration Tool Name Tool Number Fuel Tank Drain Hose 310-F013 30 Gallon Hand-Operated Fuel Tanker 034-00002 or equivalent
| WARNING | Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. |
| WARNING | When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. |
| WARNING | Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. |
| WARNING | Remove the fuel filler cap slowly. The fuel system may be under pressure. If the fuel filler cap is venting vapor or if you hear a hissing sound, wait until it stops before completely removing the fuel filler cap. Otherwise, fuel may spray out. Failure to follow these instructions may result in serious personal injury. |
- With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/explorer-sport-trac/ii-2006-2010/remont/hoistjack/#jacking-and-lifting) article.
- Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/explorer-sport-trac/ii-2006-2010/remont/body-electrical/#battery-mounting-and-cables) article.
- Release the fuel tank filler cap and position aside.
- Insert a suitable fuel drain tube into the fuel tank filler pipe until it stops.
- Insert the refueling adapter into the fuel tank filler pipe.
- Insert a suitable fuel drain tube through the refueling adapter and into the fuel tank filler pipe until it stops.
- Attach the fuel storage tanker to the fuel drain tube and remove as much fuel as possible from the fuel tank filler pipe.
- Loosen the clamp and disconnect the fuel tank filler pipe. To install, tighten to 3 Nm (27 lb-in).
- Using the special tool and the fuel tanker, siphon the fuel from the fuel tank.
Quick Connect Coupling
| Item | Specification |
|---|
| Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent (4.6L) | WSS-M2C930-A |
| Motorcraft SAE 5W-30 Premium Synthetic Blend Motor Oil XO-5W30-QSP (US); Motorcraft SAE 5W-30 Super Premium Motor Oil CXO-5W30-LSP12 (Canada); or equivalent (4.0L) | WSS-M2C929-A |
Disconnect - Type I
| WARNING | Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. |
| WARNING | Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. |
| WARNING | Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. |
| WARNING | Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. |
| WARNING | When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. |
| CAUTION | Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is essential that absolute cleanliness is observed when working with these components or component damage may occur. Always install plugs to any open orifices or tubes. |
| CAUTION | When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube or damage to the tube or connector retaining clip may occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. |
| CAUTION | Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. |
Note. During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor openings must be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials must be removed prior to installation.
- If servicing a liquid fuel tube, release the fuel system pressure. For additional information, refer to «Fuel System Pressure Release»(/ford/explorer-sport-trac/ii-2006-2010/remont/fuel-system/#fuel-system-general-information__fuel-system-pressure-release) .
- Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/explorer-sport-trac/ii-2006-2010/remont/body-electrical/#battery-mounting-and-cables) article.
- Unclip the locking tab.
- Depress the tabs and press the clip downward.
- Separate the quick connect coupling.
Connect - Type I
- Inspect the quick connect coupling and the tube for damage. Remove any dirt or obstructions.
- Connect the quick connect coupling.
- Push the clip up into the quick connect coupling. Pull on the tube to make sure it is seated correctly.
- Clip the locking tab in place.
- Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/explorer-sport-trac/ii-2006-2010/remont/body-electrical/#battery-mounting-and-cables) article.
Disconnect - Type II
| WARNING | Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. |
| WARNING | Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. |
| WARNING | Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. |
| WARNING | Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. |
| WARNING | When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. |
| CAUTION | Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is essential that absolute cleanliness is observed when working with these components or component damage may occur. Always install plugs to any open orifices or tubes. |
| CAUTION | When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube or damage to the tube or connector retaining clip may occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. |
| CAUTION | Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. |
Note. During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor openings must be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials must be removed prior to installation.
- If servicing a liquid fuel tube, release the fuel system pressure. For additional information, refer to «Fuel System Pressure Release»(/ford/explorer-sport-trac/ii-2006-2010/remont/fuel-system/#fuel-system-general-information__fuel-system-pressure-release) .
- Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/explorer-sport-trac/ii-2006-2010/remont/body-electrical/#battery-mounting-and-cables) article.
- Disconnect the fuel tube quick connect coupling. Press the fuel tube quick connect coupling button and pull the fuel tube to disconnect.
Connect - Type II
- Inspect the quick connect coupling and the tube for damage. Remove any dirt or obstructions.
- Install the quick connect coupling onto the tube until it is fully seated.
- Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/explorer-sport-trac/ii-2006-2010/remont/body-electrical/#battery-mounting-and-cables) article.
Disconnect - Type III
| WARNING | Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. |
| WARNING | Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. |
| WARNING | Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. |
| CAUTION | Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is essential that absolute cleanliness is observed when working with these components or component damage may occur. Always install plugs to any open orifices or tubes. |
| CAUTION | When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube or damage to the tube or connector retaining clip may occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. |
| CAUTION | Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. |
Note. During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor openings must be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials must be removed prior to installation.
- Release the locking tab on the quick connect coupling.
- Separate the quick connect coupling from the fitting.
Connect - Type III
- Inspect the quick connect coupling and the tube for damage. Remove any dirt or obstructions.
- Release the locking tab and install the quick connect coupling onto the fitting.
- Position the locking tab into the latched position.
Disconnect - Type IV
| WARNING | Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. |
| WARNING | Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. |
| WARNING | Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. |
| WARNING | Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. |
| WARNING | When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. |
| CAUTION | Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is essential that absolute cleanliness is observed when working with these components or component damage may occur. Always install plugs to any open orifices or tubes. |
| CAUTION | When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube or damage to the tube or connector retaining clip may occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. |
| CAUTION | Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. |
Note. During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor openings must be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials must be removed prior to installation.
- If servicing a liquid fuel tube, release the fuel system pressure. For additional information, refer to «Fuel System Pressure Release»(/ford/explorer-sport-trac/ii-2006-2010/remont/fuel-system/#fuel-system-general-information__fuel-system-pressure-release) .
- Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/explorer-sport-trac/ii-2006-2010/remont/body-electrical/#battery-mounting-and-cables) article.
- Compress the clip legs and push the clip into the quick connect coupling.
- Separate the quick connect coupling from the tube.
Connect - Type IV
- Inspect the quick connect coupling and the tube for damage. Remove any dirt or obstructions.
- Fully insert the male tube end in the quick connect coupling and push the clip downward to lock the fuel tubes together.
- Pull on the connection to make sure it is fully engaged.
- Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/explorer-sport-trac/ii-2006-2010/remont/body-electrical/#battery-mounting-and-cables) article.
Spring Lock Couplings
Special Tools Illustration Tool Name Tool Number Disconnect Tool, Spring Lock Coupling 310-S039 (T90T-9550-S) Disconnect Tool, Spring Lock Coupling 310-D005 (D87L-9280-B) or equivalent
| Item | Specification |
|---|
| Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent (4.6L) | WSS-M2C930-A |
| Motorcraft SAE 5W-30 Premium Synthetic Blend Motor Oil XO-5W30-QSP (US); Motorcraft SAE 5W-30 Super Premium Motor Oil CXO-5W30-LSP12 (Canada); or equivalent (4.0L) | WSS-M2C929-A |
| WARNING | Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. |
| WARNING | Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. |
| WARNING | Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. |
| WARNING | Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. |
| WARNING | When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. |
| CAUTION | Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is essential that absolute cleanliness is observed when working with these components or component damage may occur. Always install plugs to any open orifices or tubes. |
| CAUTION | When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube or damage to the tube or connector retaining clip may occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. |
- Release the fuel system pressure. For additional information, refer to «Fuel System Pressure Release»(/ford/explorer-sport-trac/ii-2006-2010/remont/fuel-system/#fuel-system-general-information__fuel-system-pressure-release) .
- Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/explorer-sport-trac/ii-2006-2010/remont/body-electrical/#battery-mounting-and-cables) article.
- Disconnect the safety clip from the fuel tube.
- Install the special tool and press it into the spring lock coupling.
- Separate the spring lock coupling.
- Inspect and clean both spring lock coupling ends.
- Align the fuel tube spring lock coupling and push together until a click is heard.
- Pull on the spring lock coupling to make sure it is fully seated. Install the fuel tube safety clip on the male end.
- Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/explorer-sport-trac/ii-2006-2010/remont/body-electrical/#battery-mounting-and-cables) article.
| WARNING | Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. |
| WARNING | Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. |
| WARNING | Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. |
| WARNING | When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. |
| WARNING | Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. |
| CAUTION | Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is essential that absolute cleanliness is observed when working with these components or component damage may occur. Always install plugs to any open orifices or tubes. |
| CAUTION | When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube or damage to the tube or connector retaining clip may occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. |
- Release the fuel system pressure. For additional information, refer to «Fuel System Pressure Release»(/ford/explorer-sport-trac/ii-2006-2010/remont/fuel-system/#fuel-system-general-information__fuel-system-pressure-release) .
- Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/explorer-sport-trac/ii-2006-2010/remont/body-electrical/#battery-mounting-and-cables) article.
- Remove the fuel tube safety clip.
- Install the special tool.
- Close and push the special tool into the open side of the cage.
- Separate the spring lock coupling.
- Inspect and clean both spring lock coupling ends. Install new O-ring seals and garter springs if necessary.
- Fit the male end into the female end and push until the garter spring snaps over the flared end of the female end.
- Make sure the spring lock coupling is engaged by pulling on the tube.
- Install the fuel tube safety clip.
- Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/explorer-sport-trac/ii-2006-2010/remont/body-electrical/#battery-mounting-and-cables) article.
