Fuel Tank

Removal

All vehicles

NOTE: Removal steps in this procedure may contain installation steps.

1. WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

   Refer to: Gasoline and Gasoline-Ethanol Fuel Systems Health and Safety Precautions (100-00 General Information, Description and Operation).
   

1. With the vehicle in NEUTRAL, position it on a hoist.
   Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
   

1. Release the fuel system pressure.
   Refer to: Fuel System Pressure Release (310-00B Fuel System - General Information - 3.7L Duratec (227kW/301PS), General Procedures).
   

1. Drain the fuel tank.
   Refer to: Fuel Tank Draining (310-00B Fuel System - General Information - 3.7L Duratec (227kW/301PS), General Procedures).
   

1. FWD shown, AWD similar.
   

1. FWD shown, AWD similar.
   

1. Remove the exhaust.
   Refer to: Muffler and Tailpipe (309-00B Exhaust System - 3.7L Duratec (227kW/301PS), Removal and Installation).
   

All wheel drive (AWD)

1. NOTE: Support the driveshaft.

1. NOTICE: Do not reuse the bolt and washer assemblies for the rear CV joint flange. Install new assemblies or damage to the vehicle may occur.

   Torque : 35 Nm

1. NOTICE: Do not remove driveshaft from the pinion flange by pulling on the driveshaft tube. Damage to the CV-joint can result.

   1. Index mark the rear driveshaft flange.
      
   2. Separate the driveshaft CV flange from the Rear Drive Unit (RDU) using a flat blade screwdriver in the area shown.
      
   3. Position rear of the driveshaft aside and support with mechanics wire.
      

All vehicles

1. NOTICE: Do not remove the hose clamp at the fuel tank filler pipe hose to fuel tank connection. The plastic tank is susceptible to damage with over torquing and or multiple re-torques.

   AWD shown, FWD similar.
   Refer to: Spring Lock Couplings (310-00B Fuel System - General Information - 3.7L Duratec (227kW/301PS), General Procedures).
   Refer to: Quick Release Coupling (310-00B Fuel System - General Information - 3.7L Duratec (227kW/301PS), General Procedures).
   General Equipment : Powertrain Jack
   General Equipment : Hose Clamp(s)
   Torque :
   1.   4 Nm
   2.   25 Nm

1. Lower the fuel tank far enough to disconnect the electrical connectors and vapor lines. Remove the fuel tank.
   Refer to: Quick Release Coupling (310-00B Fuel System - General Information - 3.7L Duratec (227kW/301PS), General Procedures).
   General Equipment : Powertrain Jack

Installation

1. NOTE: Prior to installing fuel tank strap bolts, make sure that the vapor lines and wire harness are positioned correctly on the top of the fuel tank.

   To install, reverse the removal procedure.
   

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