Ford Fusion: Fuel Tank and Lines - 1.5L EcoBoost (118kW/160PS) – I4 / Fuel Tank. Removal and Installation

Special Tool(s) / General Equipment

Removal

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 (310-00A Fuel System - General Information - 1.5L EcoBoost (118kW/160PS) – I4, General Procedures).
   

1. Drain the fuel tank.
   Refer to: Fuel Tank Draining (310-00A Fuel System - General Information - 1.5L EcoBoost (118kW/160PS) – I4, General Procedures).
   

1. Remove the retainers and the splash shield.
   

1. Remove the retainers and the air deflector.
   

1. Remove the retainers and the heat shield.
   

1. Remove the exhaust.
   Refer to: Muffler and Tailpipe (309-00A Exhaust System - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
   

1. If equipped.
   Remove the retainers, clip and air deflector.
   

1. Disconnect the electrical connector and position the harness aside.
   

1. Remove the retainers and the deflector.
   

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.

   • Loosen the clamp and disconnect the hose from the fuel filler pipe.
     
   • Refer to: Spring Lock Couplings (310-00A Fuel System - General Information - 1.5L EcoBoost (118kW/160PS) – I4, General Procedures).
     Refer to: Quick Release Coupling (310-00A Fuel System - General Information - 1.5L EcoBoost (118kW/160PS) – I4, General Procedures).
     
   • Remove the fuel tank strap bolts.
     Use the General Equipment: Powertrain Jack
     Use the General Equipment: Hose Clamp(s)
     Torque:
        1.:   35 lb.in (4 Nm)
        2.:   18 lb.ft (25 Nm)

1. Lower the fuel tank far enough to disconnect the electrical connector and vapor lines. Remove the fuel tank.
   Refer to: Quick Release Coupling (310-00A Fuel System - General Information - 1.5L EcoBoost (118kW/160PS) – I4, General Procedures).
   Use the General Equipment: Powertrain Jack

Installation

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

   To install, reverse the removal procedure.