Extended Range Tank

Special Tool(s):

SPECIAL TOOL(S)

REMOVAL
1. If removing the fuel tank for replacement of the fuel tank or the fuel tank solenoid valve, perform the Pressure Relief - Fuel Tank Venting procedure.







2. If removing the fuel tank for replacement of lines, turn in the manual lockdown valve jackscrew on the fuel tank solenoid valve.

NOTE: The jackscrew on the extended range fuel tank is accessed through an access hole in the vapor retaining cover.

3. Perform the Pressure Relief - Fuel Line Venting procedure.
4. Disconnect the battery ground cable.
5. Raise and support the vehicle.







6. Disconnect the electrical connectors.







7. Disconnect the upper fuel line and the flexible tube retainer.
1 Loosen the fitting and disconnect the upper fuel line.
2 Remove the nuts and position the fuel lines and wiring harness into the luggage compartment.

NOTE: Loosen the fittings slowly to allow any excess line pressure to vent through the fitting connection.

8. Lower the vehicle.
9. Remove the rear seat.







10. Remove the bolts and nuts.







11. Remove the bolts and the partition separator.







12. Remove the bolts.







13. Remove the bolts and the frame and shield assembly.







14. Remove the bolts







15. Remove the bolts and the fuel tank straps.







16. Install the lifting equipment and remove the extended range fuel tank.

INSTALLATION
1. To install, follow the removal procedure in reverse order.
^ Perform the Fuel System Leak Test procedure. Component Tests and General Diagnostics

NOTE:
^ Replace the fuel line O-ring seal.
^ Lubricate O-rings seal with Super Premium 5W-30 engine oil meeting Ford specification WSS-M2C153-G or equivalent prior to installation to help seal and ease installation.
^ When tightening the fuel line, a torque wrench adapter must be used with the torque wrench. The use of a torque wrench adapter will alter the effective torque of the torque wrench being used. To correct the effective torque, a torque multiplication conversion must be used.