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Fuel Tank & Fuel Lines Ford Five Hundred I

Fuel System 12 illustrations ~2049 words

GENERAL SPECIFICATIONS

ItemSpecification
Lubricant
SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (in Canada Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12) or equivalentWSS-M2C930-A

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

DescriptionNm
Fuel tank strap bolts35
Fuel tank filler pipe bolt9
Fuel tank filler pipe hose clamp3
Fuel tank filler pipe mounting screws3
Fuel filter bracket bolt9
Fuel tube retainer clip bolt20
Inertia fuel shutoff (IFS) switch bolts12
Rear seat latch bracket bolts17

TORQUE SPECIFICATIONS

Fuel Tank and Lines

The fuel tank and lines consists of

  1. a dual-container (saddle-type) high density polyethelene fuel tank.
  2. a fuel level sensor in the left fuel tank half to transfer fuel from the left to the right, which contains the fuel pump module that supplies fuel under pressure to the fuel rail.
  3. a fuel tank filler pipe which contains a restrictor plate to permit only unleaded fuel to be pumped into the fuel tank.
  4. a fuel tank filler pipe assembly that cannot be modified in any way. The fuel tank filler pipe is serviced only by installing a new filler pipe assembly.
  5. a 1/4 turn fuel tank filler cap.
  6. an electronic returnless fuel system.
  7. a fuel filter that is mounted in front of the fuel tank on the right hand side of the vehicle providing filtration to protect the fuel injectors.
  8. fuel tubes (liquid and vapor) combined in a bundle along with the brake lines mounted on the underside of the floorpan and covered with a protective cover shield.
  9. quick connect fuel tube couplings.

The fuel pump is controlled by powertrain control module (PCM). Electrical power to the pump is provided through the inertia fuel shutoff (IFS) switch located in the passenger footwell area.

Refer to the INTRODUCTION - GASOLINE article .

Scheme 5

Scheme 5: Fuel Tank and Filler Pipe - Exploded View
Scheme 5: Fuel Tank and Filler Pipe - Exploded View
  1. For additional information, refer to the procedures below.

Removal and Installation

WARNINGDo not smoke or carry lighted tobacco or an 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.
WARNINGDo not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.
WARNINGFuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.
WARNINGThis procedure involves fuel handling. Be prepared for spillage at all times and always observe fuel handling precautions. Failure to follow these instructions can result in personal injury.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
  2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/fuel-system/#fuel-system-general-information) .
  3. Drain the fuel tank. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/fuel-system/#fuel-system-general-information) .
  4. Remove the rear driveshaft. For additional information, refer to «DRIVELINE SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/axle-shafts/#driveline-system-general-information) .
  5. Remove the muffler. For additional information, refer to «EXHAUST SYSTEM»(/ford/five-hundred/i-2004-2007/remont/exhaust/#exhaust-system) .
  6. Disconnect the fuel vapor control tube assembly valve-to-fuel vapor tube quick connect coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/fuel-system/#fuel-system-general-information) .
  7. Disconnect the fuel supply tube-to-fuel filter quick connect coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/fuel-system/#fuel-system-general-information) .
  8. Disconnect the fuel vapor tube-to-fuel vapor control tube assembly valve quick connect coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/fuel-system/#fuel-system-general-information) .
  9. Disconnect the fuel tank wiring harness electrical connector at the rear of the fuel tank.
  10. Release the clamp and remove the fuel tank filler hose from the fuel tank.
  11. Place a suitable lifting device under the fuel tank.
  12. Remove the 2 front fuel tank strap bolts. To install, tighten to 35 Nm (26 lb-ft).
  13. Loosen the 2 rear fuel tank strap bolts and position the 2 fuel tank straps aside.
  14. Lower the fuel tank enough to move forward, clear of the fuel straps then complete the lowering procedure.
  15. To install, reverse the removal procedure.

Special Tool(s)

SPECIAL TOOL DESCRIPTION Fuel Storage Tanker 164-R3202 or equivalent

Scheme 6

Scheme 6: Special Tool(s)
Scheme 6: Special Tool(s)
WARNINGDo not smoke or carry lighted tobacco or an 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.
WARNINGDo not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.

Scheme 7

Scheme 7
Scheme 7
  1. Remove the evaporative emission (EVAP) canister. For additional information, refer to «EVAPORATIVE EMISSIONS»(/ford/five-hundred/i-2004-2007/remont/auxiliary-emission-control-systems/#evaporative-emissions) .
  2. Remove the fuel tank filler cap.
  3. Insert a suitable fuel drain tube into the fuel tank filler pipe until it reaches the fuel tank inlet spout.
  4. Attach the fuel storage tanker to the fuel drain tube and remove any residual fuel in the fuel tank filler pipe.
  5. Remove the 2 fuel tank filler pipe upper retaining screws. To install, tighten to 3 Nm (27 lb-in).
  6. Remove the fuel tank filler pipe lower retaining bolt. To install, tighten to 9 Nm (80 lb-in).
  7. Remove the RH rear inner fender splash shield.
  8. Disconnect the fuel tank filler pipe vapor tube-to-fuel vapor control tube assembly valve quick connect coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/fuel-system/#fuel-system-general-information) .
  9. Release the clamp and remove the fuel tank filler hose from the fuel tank.
  10. Remove the fuel tank filler pipe from the vehicle.
  11. To install, reverse the removal procedure.

SPECIAL TOOL DESCRIPTION Lock Ring Wrench 310-123 Fuel Storage Tanker 164-R3202 or equivalent

Material

ItemSpecification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (in Canada Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12) or equivalentWSS-M2C930-A

MATERIAL SPECIFICATIONS

Scheme 8

Scheme 8
Scheme 8
WARNINGDo 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 may be ignited. Failure to follow these instructions can result in personal injury.
WARNINGDo not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.
WARNINGFuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel causing personal injury or a fire hazard.

Scheme 9

Scheme 9
Scheme 9

Scheme 10

Scheme 10
Scheme 10

Scheme 11

Scheme 11
Scheme 11
  1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
  2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/fuel-system/#fuel-system-general-information) .
  3. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/five-hundred/i-2004-2007/remont/charging-system/#battery-mounting-and-cables) .
  4. Remove the fuel tank filler cap.
  5. Insert a suitable fuel drain tube into the fuel tank filler pipe until it reaches the fuel tank inlet spout.
  6. Attach the fuel storage tanker to the fuel drain tube and remove any residual fuel in the fuel tank filler pipe.
  7. Release the clamp and remove the fuel tank filler pipe hose from the fuel tank inlet spout.
  8. Insert a suitable fuel drain tube into the fuel tank inlet spout.
  9. Attach the fuel storage tanker to the fuel drain tube and drain the fuel from the RH side of the fuel tank.
  10. Remove the rear lower seat cushion. Release the latches and pull upward on the rear lower seat cushion and remove.
  11. Position the second row seat forward.
  12. Remove the bolt and the LH third row rear seat load floor support. To install, tighten to 17 Nm (13 lb-ft).
  13. Remove the LH second row seat belt anchor bolt. To install, tighten to 30 Nm (20 lb-ft).
  14. Position any carpet and/or insulation covering the fuel pump module access cover aside.
  15. Remove the fuel pump module access cover.
  16. Clean the surrounding area of the fuel pump module mounting flange and the quick connect couplings with compressed air.
  17. Disconnect the fuel pump module electrical connector.
  18. Disconnect the fuel supply tube-to-fuel pump module quick connect coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/fuel-system/#fuel-system-general-information) .
  19. Disconnect the fuel vapor tube-to-fuel pump module quick connect coupling from the top of the fuel pump module. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/fuel-system/#fuel-system-general-information) .
  20. Install the special tool and remove the fuel pump module lock ring.
  21. Carefully lift the fuel pump module out of the fuel tank allowing access to disconnect the quick connect couplings.
  22. Disconnect the fuel supply tube-to-fuel pump module quick connect coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/fuel-system/#fuel-system-general-information) .
  23. Disconnect the fuel vapor tube-to-fuel pump module quick connect coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/fuel-system/#fuel-system-general-information) .
  24. Completely remove the fuel pump module from the fuel tank.
  25. Remove the fuel pump module O-ring seal.
  26. To install, reverse the removal procedure. Make sure the alignment arrows on the fuel pump module and the fuel tank meet before tightening the fuel pump module lock ring.

SPECIAL TOOL DESCRIPTION Lock Ring Wrench 310-123 Fuel Storage Tanker 164-R3202 or equivalent

ItemSpecification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (in Canada Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12) or equivalentWSS-M2C930-A

MATERIAL SPECIFICATIONS

Scheme 12

Scheme 12: Removal and Installation
Scheme 12: Removal and Installation
WARNINGDo 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 may be ignited. Failure to follow these instructions can result in personal injury.
WARNINGDo not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.
WARNINGFuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel causing personal injury or a fire hazard.

Scheme 13

Scheme 13
Scheme 13
  1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
  2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/fuel-system/#fuel-system-general-information) .
  3. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/five-hundred/i-2004-2007/remont/charging-system/#battery-mounting-and-cables) .
  4. Remove the fuel tank filler cap.
  5. Insert a suitable fuel drain tube into the fuel tank filler pipe until it reaches the fuel tank inlet spout.
  6. Attach the fuel storage tanker to the fuel drain tube and remove any residual fuel in the fuel tank filler pipe.
  7. Release the clamp and remove the fuel tank filler pipe hose from the fuel tank inlet spout.
  8. Insert a suitable fuel drain tube into the fuel tank inlet spout.
  9. Attach the fuel storage tanker to the fuel drain tube and drain the fuel from the RH side of the fuel tank.
  10. Remove the rear lower seat cushion. Release the latches and pull upward on the rear lower seat cushion and remove.
  11. Position the second row seat forward.
  12. Remove the bolt and the LH third row rear seat load floor support. To install, tighten to 17 Nm (13 lb-ft).
  13. Remove the LH second row seat belt anchor bolt. To install, tighten to 30 Nm (20 lb-ft).
  14. Position any carpet and/or insulation covering the fuel level sensor access cover aside.
  15. Remove the fuel level sensor access cover.
  16. Clean the surrounding area of the fuel level sensor mounting flange.
  17. Disconnect the fuel level sensor electrical connector.
  18. Install the special tool and remove the fuel level sensor lock ring.
  19. Carefully lift the fuel level sensor out of the fuel tank allowing access to disconnect the quick connect coupling.
  20. Disconnect the fuel supply tube-to-fuel level sensor quick connect coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/fuel-system/#fuel-system-general-information) .
  21. Completely remove the fuel level sensor from the fuel tank.
  22. Remove the fuel level sensor O-ring seal.
  23. To install, reverse the removal procedure. Make sure the alignment arrows on the fuel level sensor and the fuel tank meet before tightening the fuel level sensor lock ring.

Scheme 14

Scheme 14: Fuel Lines and Fuel Filter - Exploded View
Scheme 14: Fuel Lines and Fuel Filter - Exploded View

Scheme 15

Scheme 15
Scheme 15
  1. For additional information, refer to the procedures in this article.
WARNINGDo not smoke or carry lighted tobacco or an 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.
WARNINGDo not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.
WARNINGFuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.
WARNINGThis procedure involves fuel handling. Be prepared for spillage at all times and always observe fuel handling precautions. Failure to follow these instructions can result in personal injury.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
  2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/fuel-system/#fuel-system-general-information) .
  3. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/five-hundred/i-2004-2007/remont/charging-system/#battery-mounting-and-cables) .
  4. Remove the generator. For additional information, refer to «GENERATOR AND REGULATOR»(/ford/five-hundred/i-2004-2007/remont/charging-system/#charging-system-generator-regulator) .
  5. Remove the evaporative emission (EVAP) canister purge valve. For additional information, refer to «EVAPORATIVE EMISSIONS»(/ford/five-hundred/i-2004-2007/remont/auxiliary-emission-control-systems/#evaporative-emissions) .
  6. Detach the fuel supply tube retainer from the upper intake manifold.
  7. Disconnect the fuel supply tube-to-fuel rail quick connect coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/fuel-system/#fuel-system-general-information) .
  8. Remove the fuel tube retainer bolt. To install, tighten to 20 Nm (15 lb-ft).
  9. Remove the fuel tube retainer shield. Loosen the 3 retainer shield nuts. Remove the retainer shield.
  10. Disconnect the fuel vapor tube assembly valve-to-vapor tube quick connect coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/fuel-system/#fuel-system-general-information) .
  11. Disconnect the 2 fuel supply tube-to-fuel filter quick connect couplings. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/fuel-system/#fuel-system-general-information) .
  12. Remove the rear lower seat cushion. Release the latches and pull upward on the rear lower seat cushion and remove.
  13. Position the second row seats rearward.
  14. Remove the rear seat latching brackets. Remove the latching bracket bolts. Remove the latching brackets. To install, tighten to 17 Nm (13 lb-ft).
  15. Remove the fuel pump module access cover.
  16. Clean the surrounding area of the fuel pump module mounting flange and the quick connect couplings with compressed air.
  17. Disconnect the fuel supply tube-to-fuel pump module quick connect coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/fuel-system/#fuel-system-general-information) .
  18. Disconnect the fuel vapor tube assembly valve-to-fuel pump module quick connect coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/fuel-system/#fuel-system-general-information) .
  19. Disconnect the fuel vapor tube assembly valve electrical connector.
  20. Disconnect the fuel vapor tube assembly valve-to-EVAP canister tube quick connect coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/fuel-system/#fuel-system-general-information) .
  21. Disconnect the fuel vapor tube-to-EVAP canister quick connect coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/fuel-system/#fuel-system-general-information) .
  22. Disconnect the fuel vapor tube-to-fuel tank filler pipe vapor tube quick connect coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/fuel-system/#fuel-system-general-information) .
  23. Release the fuel tube assembly from the fuel tube retainers.
  24. Remove the fuel tube assembly.
  25. To install, reverse the removal procedure.
WARNINGDo not smoke or carry lighted tobacco or an 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.
WARNINGDo not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.
WARNINGFuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.
WARNINGThis procedure involves fuel handling. Be prepared for spillage at all times and always observe fuel handling precautions. Failure to follow these instructions can result in personal injury.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
  2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/fuel-system/#fuel-system-general-information) .
  3. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/five-hundred/i-2004-2007/remont/charging-system/#battery-mounting-and-cables) .
  4. Disconnect the fuel supply tube-to-fuel filter inlet quick connect coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/fuel-system/#fuel-system-general-information) .
  5. Disconnect the fuel supply tube-to-fuel filter outlet quick connect coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/fuel-system/#fuel-system-general-information) .
  6. Loosen the fuel filter retaining clamp. To install, tighten to 3 Nm (27 lb-in).
  7. Remove the fuel filter.
  8. To install, reverse the removal procedure.

Scheme 16

Scheme 16: Inertia Fuel Shutoff (IFS) Switch
Scheme 16: Inertia Fuel Shutoff (IFS) Switch
  1. Disconnect the battery ground cable. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
  2. Remove the RH cowl side trim panel. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/five-hundred/i-2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
  3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector.
  4. Remove the 2 IFS switch retaining bolts. To install, tighten to 12 Nm (9 lb-ft).
  5. Remove the IFS switch.
  6. To install, reverse the removal procedure.

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