Fuel System: Removal & Installation Ford Explorer III

Item 14: Fuel Filler Pipe Removal Note

1. Slightly lower the fuel tank.

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1. Unclip the tab.
2. Depress the tabs and press the clip downward.
3. Separate the fittings.

Scheme 18

1. Install the special tool.

Item 4: Push Connect Fitting Installation Note

1. Align the fuel line fitting and press together until a click is heard. Pull on the fitting to make sure it is fully engaged, then install the safety clip.

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1. Disconnect the battery ground cable. For additional information, refer to «BATTERY AND CHARGING SYSTEM»(ref-194056) .
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-194052-S35121267512005092600000) .
3. Remove the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION»(ref-194049) .
4. Remove the components in the order indicated in the following illustration and table. To remove individual components, only carry out the listed steps.
5. To install, reverse the removal procedure.

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1. Install the spring lock coupling disconnect tool.
2. Press the spring lock coupling disconnect tool into the open end of the cage.
3. Separate the fuel line fitting.

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1. Disconnect the safety clip from the fuel line.
2. Install the special tool and press it into the fitting.
3. Separate the fittings.

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1. Unclip the tab.
2. Depress the tabs and press the clip downward.
3. Separate the fittings.

Scheme 32

1. NOTE: Lubricate the fuel fitting with clean engine oil. Align the fuel line fitting and press together until a click is heard. Pull on the fitting to make sure it is fully engaged, then install the safety clip.

Scheme 33

1. Clean and inspect the coupling ends and lubricate the O-rings with clean engine oil.

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1. WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and can be ignited, resulting in possible personal injury. WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard. Disconnect the battery ground cable. For additional information, refer to «BATTERY AND CHARGING SYSTEM»(ref-194056) .
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-194052-S35121267512005092600000) .
3. Remove the components in the order indicated in the following illustration and table. To remove individual components, only carry out the listed steps.
4. To install, reverse the removal procedure.

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1. Install the spring lock coupling disconnect tool.
2. Press the spring lock coupling disconnect tool into the open end of the cage.
3. Separate the fuel line fitting.

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Scheme 43

1. Disconnect the safety clip from the fuel line.
2. Install the special tool and press it into the fitting.
3. Separate the fittings.

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Scheme 46

1. Unclip the tab.
2. Depress the tabs and press the clip downward.
3. Separate the fittings.

Item 7: Push Connect Fitting Installation Note

1. Align the fuel line fitting and press together until a click is heard. Pull on the fitting to make sure it is fully engaged, then install the safety clip.

Scheme 47

1. Clean and inspect the coupling ends and lubricate the O-rings with clean engine oil.

Scheme 48

1. Remove the components in the order indicated in the following illustration and table.
2. To install, reverse the removal procedure.

Scheme 49

1. Remove the components in the order indicated in the following illustration and table.
2. To install, reverse the removal procedure.

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Scheme 55

1. Remove the accelerator cable from the rubber plunger.
2. Position the rubber plunger rearward and remove the cable from the accelerator pedal.
3. Rotate the throttle cam and disconnect the accelerator cable.
4. Squeeze the tabs and remove the accelerator cable from the bracket.
5. Disconnect the accelerator cable routing clips in two locations.
6. Pull the accelerator cable boot to the unlock position and remove the accelerator cable.

Scheme 56

1. Remove the components in the order indicated in the following illustration and table.
2. To install, reverse the removal procedure.

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Scheme 61

1. Remove the accelerator cable from the rubber plunger.
2. Position the rubber plunger rearward and remove the cable from the accelerator pedal.
3. Disconnect the accelerator cable from the throttle body.
4. Squeeze the tabs and remove the accelerator cable from the bracket.
5. Pull the accelerator cable boot to the unlock position and remove the accelerator cable.

Scheme 62

1. Remove the components in the order indicated in the following illustration and table.
2. To install, reverse the removal procedure.

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1. Remove the accelerator cable from the rubber plunger.
2. Position the rubber plunger rearward and remove the cable from the accelerator pedal.

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1. Disconnect the battery ground cable. For additional information, refer to «BATTERY AND CHARGING SYSTEM»(ref-194056) .
2. With the vehicle in NEUTRAL, position on a hoist.
3. To remove individual components, only carry out the listed steps.
4. Illustration 1 of 2. Remove the components in the order indicated in the following illustration and table.
5. Illustration 2 of 2. Remove the components in the order indicated in the following illustration and table.
6. To install, reverse the removal procedure.
7. Leak test the evaporative emission system. For additional information, refer to «EVAPORATIVE EMISSION SYSTEM LEAK TEST»(ref-194052-S04792009142005092600000) .
8. Carry out the evaporative emission repair drive cycle. For additional information, refer to «EVAPORATIVE EMISSION REPAIR VERIFICATION DRIVE CYCLE»(ref-194052-S13379953532005092600000) .

Item 6: Fuel Tank Removal Note

1. Remove the fuel tank. For additional information, refer to «FUEL TANK AND FILLER PIPE»(ref-194052-S11901303862005092600000) .

Scheme 68

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY AND CHARGING SYSTEM»(ref-194056) .
2. With the vehicle in NEUTRAL, position on a hoist.
3. Remove the components in the order indicated in the following illustration and table.
4. To install, reverse the removal procedure.
5. Leak test the evaporative emission system. For additional information, refer to «EVAPORATIVE EMISSION SYSTEM LEAK TEST»(ref-194052-S04792009142005092600000) .
6. Carry out the evaporative emission repair drive cycle. For additional information, refer to «EVAPORATIVE EMISSION REPAIR VERIFICATION DRIVE CYCLE»(ref-194052-S13379953532005092600000) .

Scheme 69

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY AND CHARGING SYSTEM»(ref-194056) .
2. With the vehicle in NEUTRAL, position on a hoist.
3. Remove the components in the order indicated in the following illustration and table.
4. To install, reverse the removal procedure.

Scheme 70

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY AND CHARGING SYSTEM»(ref-194056) .
2. With the vehicle in NEUTRAL, position on a hoist.
3. Remove the evaporative (EVAP) canister solenoid. For additional information, refer to «EVAPORATIVE EMISSION CANISTER AND PURGE VALVE»(ref-194052-S29280083992005092600000) .
4. Remove the components in the order indicated in the following illustration and table.
5. To install, reverse the removal procedure.
6. Leak test the evaporative emission system. For additional information, refer to «EVAPORATIVE EMISSION SYSTEM LEAK TEST»(ref-194052-S04792009142005092600000) .
7. Carry out the evaporative emission repair drive cycle. For additional information, refer to «EVAPORATIVE EMISSION REPAIR VERIFICATION DRIVE CYCLE»(ref-194052-S13379953532005092600000) .