Fuel Tank and Fuel Lines Ford Taurus X I

Material

Material

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS TABLE

TORQUE SPECIFICATIONS TABLE

Fuel Tank and Lines

The fuel tank and lines consists of the

1. All-Wheel Drive (AWD) saddle-type fuel tank or a FWD L-shaped fuel tank.
2. fuel tank filler pipe.
3. fuel tank filler cap.
4. Fuel Pump (FP) module.
5. fuel level sensor assembly (saddle-tank only).
6. fuel level sender (mounted on FP and, if equipped, the fuel level sensor assembly).
7. fuel tubes.
8. Fuel Tank Pressure (FTP) sensor.
9. Inertia Fuel Shutoff (IFS) switch.

The vehicle

1. uses a Mechanical Returnless Fuel System (MRFS).
2. uses either a single container (L-shaped) or a dual-container (saddle-type) fuel tank.
3. has a fuel level sensor assembly (saddle-tank only).
4. has a FP module that supplies fuel under pressure to the fuel rail.
5. has a fuel filter (part of the FP module).
6. has fuel tubes (liquid and vapor) along with brake tubes mounted on the underside of the vehicle in a bundle.
7. has a FTP sensor (part of the fuel vapor tube assembly).
8. fuel injection rail pressure is controlled by the electronic FP module which is enabled by the PCM.
9. has a one-fourth turn vented type fuel tank filler cap.
10. has a fuel tank filler pipe assembly, which cannot be modified in any way and is serviced only by installation of a new fuel tank filler pipe assembly.
11. has an IFS switch located in the passenger side footwell that shuts off fuel in the event of a collision.
12. has a fuel level vent valve (part of the FP module on Taurus X federal emission vehicles, part of the fuel tank on all other vehicles).
13. has a serviceable fuel level sender mounted on the FP module.
14. has a serviceable fuel level sender mounted on the fuel level sensor assembly (saddle-tank only).

The FP is controlled by the PCM. Electrical power to the FP is provided through the IFS switch.

Refer to the Introduction - Gasoline Engines article.

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Scheme 9

1. For additional information, refer to the procedures in this article.

REMOVAL AND INSTALLATION

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/taurus-x/i-2007-2009/remont/hoistjack/#jacking-and-lifting) article.
2. Drain the fuel tank. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information) article.
3. Remove the muffler and tailpipe assembly. For additional information, refer to «EXHAUST SYSTEM»(/ford/taurus-x/i-2007-2009/remont/exhaust/#exhaust-system) article.
4. Release the clamp and remove the fuel tank filler pipe hose from the fuel tank. To install, tighten to 3 Nm (27 lb-in).
5. Disconnect the Evaporative Emission (EVAP) canister fresh air hose-to-fuel tank filler pipe fresh air tube quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information) article.
6. Disconnect the fuel vapor tube assembly-to-fuel tank filler pipe recirculation tube quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information) article.
7. Disconnect the fuel tank wire harness electrical connector and release the fuel tank wire harness retainer.
8. Disconnect the fuel tank jumper tube-to-fuel tube quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information) article.
9. Disconnect the EVAP canister vent solenoid electrical connector.
10. Disconnect the fresh air hose-to-dust separator fitting.
11. Disconnect the fuel vapor tube assembly-to-EVAP canister quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information) article.
12. Position a suitable lifting device under the fuel tank.
13. Remove the 4 fuel tank strap bolts. To install, tighten to 35 Nm (26 lb-ft).
14. Remove the fuel tank.
15. To install, reverse the removal procedure.

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/taurus-x/i-2007-2009/remont/hoistjack/#jacking-and-lifting) article.
2. Remove the muffler and tailpipe. For additional information, refer to «EXHAUST SYSTEM»(/ford/taurus-x/i-2007-2009/remont/exhaust/#exhaust-system) article.
3. Drain the fuel tank. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information) article.
4. Remove the driveshaft. For additional information, refer to «DRIVESHAFT»(/ford/taurus-x/i-2007-2009/remont/driveshaft-universal-joints/#driveshaft) article.
5. Release the clamp and remove the fuel tank filler pipe hose from the fuel tank. To install, tighten to 3 Nm (27 lb-in).
6. Disconnect the Evaporative Emission (EVAP) canister fresh air tube-to-fuel tank filler pipe fresh air tube quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information) article.
7. Disconnect the fuel vapor tube assembly-to-fuel tank filler pipe recirculation tube quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information) article.
8. Disconnect the fuel tank wire harness electrical connector and release the fuel tank wire harness retainer.
9. Disconnect the fuel tank jumper tube-to-fuel tube quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information) article.
10. Remove the EVAP canister. For additional information, refer to «EVAPORATIVE EMISSIONS»(/ford/taurus-x/i-2007-2009/remont/auxiliary-emission-control-systems/#evaporative-emissions-system) article.
11. Position a suitable lifting device under the fuel tank.
12. Remove the 4 fuel tank strap bolts. To install, tighten to 35 Nm (26 lb-ft).
13. Remove the fuel tank.
14. To install, reverse the removal procedure.

Fuel Tank Filler Pipe

Special Tools Illustration Tool Name Tool Number Fuel Draining Hose 310-102 Fuel Storage Tanker 164-R3202 or equivalent

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/taurus-x/i-2007-2009/remont/hoistjack/#jacking-and-lifting) article.
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/taurus-x/i-2007-2009/remont/body-electrical/#battery-mounting-and-cables) article.
3. Carefully turn the fuel tank filler cap counterclockwise approximately one-fourth turn until the thread disengages and position aside.
4. Insert the Fuel Draining Hose into the fuel tank filler pipe. Attach the Fuel Storage Tanker to the Fuel Draining Hose and remove as much fuel as possible from the fuel tank and filler pipe, lowering the fuel level below the tank inlet spout.
5. Release the clamp and remove the fuel tank filler pipe hose from the fuel tank. To install, tighten to 3 Nm (27 lb-in).
6. Disconnect the Evaporative Emission (EVAP) canister fresh air hose-to-fuel tank filler pipe fresh air tube quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information) article.
7. Disconnect the fuel vapor tube assembly-to-fuel tank filler pipe recirculation tube quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information) article.
8. Remove the fuel tank filler pipe bracket bolt. To install, tighten to 9 Nm (80 lb-in).
9. Remove the 2 fuel tank filler pipe retaining screws. To install, tighten to 3 Nm (27 lb-in).
10. Remove the RH rear wheel and tire. For additional information, refer to «WHEELS AND TIRES»(/ford/taurus-x/i-2007-2009/remont/wheel-tire-system/#wheels-tires) article.
11. Remove the 3 screws, 2 rivets and the RH rear fender splash shield.
12. Disconnect the fuel tank filler pipe fresh air hose-to-fuel fill door housing fitting.
13. Remove the fuel tank filler pipe.
14. To install, reverse the removal procedure.

Fuel Pump Module

Special Tools Illustration Tool Name Tool Number Fuel Draining Hose 310-102 Fuel Storage Tanker 164-R3202 or equivalent Fuel Tank Sender Unit Wrench 310-123

Material

Note. The Fuel Pump (FP) module has a serviceable fuel level sender. For additional information, refer to Fuel Level Sender .

All vehicles

1. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information) article.
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/taurus-x/i-2007-2009/remont/body-electrical/#battery-mounting-and-cables) article.
3. Carefully turn the fuel tank filler cap counterclockwise approximately one-fourth turn until the thread disengages and position aside.
4. Insert the Fuel Draining Hose into the fuel tank filler pipe. Attach the Fuel Storage Tanker to the Fuel Draining Hose and remove as much fuel as possible from the fuel tank and filler pipe, lowering the fuel level below the FP module mounting flange.
5. Remove the rear seat lower cushion. For additional information, refer to «SEATING»(/ford/taurus-x/i-2007-2009/remont/seats/#seat-system) article.
6. Release the 2 load floor support brackets and position the load floor upward.
7. Remove the 4 load floor support-to-floor pan nuts. To install, tighten to 18 Nm (159 lb-in).
8. Remove the 2 load floor support brackets.
9. Remove the FP module access cover.
10. Disconnect the FP module electrical connector.
11. Disconnect the FP module quick connect coupling(s). For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information) article.
12. Remove the driveshaft. For additional information, refer to «DRIVESHAFT»(/ford/taurus-x/i-2007-2009/remont/driveshaft-universal-joints/#driveshaft) article.
13. Disconnect the fuel tank jumper tube-to-fuel tube quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information) article.
14. Remove the Evaporative Emission (EVAP) canister. For additional information, refer to «EVAPORATIVE EMISSIONS»(/ford/taurus-x/i-2007-2009/remont/auxiliary-emission-control-systems/#evaporative-emissions-system) article.
15. Position a suitable lifting device under the fuel tank.
16. Remove the 2 front fuel tank strap bolts. To install, tighten to 35 Nm (26 lb-ft).
17. Partially lower the front of the fuel tank for access and remove the FP module shield.
18. Remove the 3 nuts and the FP module shield. To install, tighten to 9 Nm (80 lb-in).
19. Raise the fuel tank into the installed position and reinstall the 2 fuel tank strap bolts.
20. Install the Fuel Tank Sender Unit Wrench, remove and discard the FP module lock ring.
21. Carefully lift the FP module out of the fuel tank allowing access and disconnect the FP module internal quick connect coupling(s). For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information) article.
22. Completely remove the FP module from the fuel tank.
23. Remove and discard the FP module O-ring seal.
24. To install, reverse the removal procedure. Make sure the alignment arrows on the fuel pump module and the fuel tank meet before tightening the FP module lock ring. Tighten the FP lock ring until it meets the stop tabs on the fuel tank.

Fuel Level Sensor

Special Tools Illustration Tool Name Tool Number Fuel Draining Hose 310-102 Fuel Storage Tanker 164-R3202 or equivalent Fuel Tank Sender Unit Wrench 310-123

Material

Note. The fuel level sensor has a serviceable fuel level sender. For additional information, refer to Fuel Level Sender .

All vehicles

1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/taurus-x/i-2007-2009/remont/hoistjack/#jacking-and-lifting) article.
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information) article.
3. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/taurus-x/i-2007-2009/remont/body-electrical/#battery-mounting-and-cables) article.
4. Carefully turn the fuel tank filler cap counterclockwise approximately one-fourth turn until the thread disengages and position aside.
5. Insert the Fuel Draining Hose into the fuel tank filler pipe. Attach the Fuel Storage Tanker to the Fuel Draining Hose and remove as much fuel as possible from the fuel tank and filler pipe, lowering the fuel level below the fuel level sensor mounting flange.
6. Remove the rear seat lower cushion. For additional information, refer to «SEATING»(/ford/taurus-x/i-2007-2009/remont/seats/#seat-system) article.
7. Release the 2 load floor support brackets and position the load floor upward.
8. Remove the 4 load floor support-to-floor pan nuts. To install, tighten to 18 Nm (159 lb-in).
9. Remove the 2 load floor support brackets.
10. Remove the fuel level sensor access cover.
11. Disconnect the fuel level sensor electrical connector.
12. Install the Fuel Tank Sender Unit Wrench, remove and discard the fuel level sensor lock ring.
13. Carefully lift the fuel level sensor out of the fuel tank allowing access and disconnect the quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information) article.
14. Remove the fuel level sensor from the fuel tank.
15. Remove and discard the fuel level sensor O-ring seal.
16. 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. Tighten the fuel level sensor lock ring until it meets the stop tabs on the fuel tank.

Scheme 10

Scheme 11

1. Remove either the Fuel Pump (FP) module or fuel level sensor assembly. For additional information, refer to «Fuel Pump Module»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-tank-and-fuel-lines__fuel-pump-module) or «Fuel Level Sensor»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-tank-and-fuel-lines__fuel-level-sensor) .
2. Disconnect the fuel level sender electrical connector.
3. Depress the lock tab and slide the fuel level sender upwards and remove.
4. To install, reverse the removal procedure.

Scheme 12

1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/taurus-x/i-2007-2009/remont/hoistjack/#jacking-and-lifting) article.
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information) article.
3. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/taurus-x/i-2007-2009/remont/body-electrical/#battery-mounting-and-cables) article.
4. Disconnect the fuel supply tube-to-fuel rail jumper tube quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information) article.
5. Disconnect the fuel vapor tube-to-Evaporative Emission (EVAP) canister purge valve quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information) article.
6. Remove the bolt and release the fuel tubes from the bundle retainer. To install, tighten to 20 Nm (177 lb-in).
7. Disconnect the fuel tube-to-fuel jumper tube quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(/ford/taurus-x/i-2007-2009/remont/fuel-system/#fuel-system-general-information) article.
8. Remove and discard the EVAP canister rivet.
9. Remove the nut and position the fuel tube bundle shield and the EVAP canister shield aside.
10. Release the fuel tubes from the fuel tube bundle shield and remove the tubes.
11. To install, reverse the removal procedure.

Scheme 13

1. Remove the RH cowl side trim panel. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/taurus-x/i-2007-2009/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) article.
2. Disconnect the Inertia Fuel Shutoff (IFS) switch electrical connector.
3. Remove the 2 bolts and the IFS switch. To install, tighten to 12 Nm (106 lb-in).
4. To install, reverse the removal procedure.

See also:
• Introduction - Gasoline Engines
• JACKING AND LIFTING
• FUEL SYSTEM - GENERAL INFORMATION
• EXHAUST SYSTEM
• DRIVESHAFT
• EVAPORATIVE EMISSIONS
• BATTERY, MOUNTING AND CABLES
• WHEELS AND TIRES
• SEATING
• INTERIOR TRIM AND ORNAMENTATION
• Fuel Level Sender
• Fuel Pump Module
• Fuel Level Sensor