Upper

REMOVAL
1. Perform fuel pressure release.
2. Disconnect battery ground cable.

NOTE: When the battery has been disconnected or reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.

3. Remove upper fuel tank rack interior luggage compartment close-out trim to expose tank rack assembly.
4. Remove luggage compartment rear opening trim plate.
5. Remove three nylon retaining nuts and remove flexible tube closeout shield.
6. Remove luggage compartment lamp.
7. Raise vehicle.
8. Remove LH rear wheel and tire assembly.
9. Remove four pushpins and remove lower splash flap.
10. Vent fuel lines as described.
11. Slowly loosen fuel line tube nut fitting on fuel line to upper tank rack assembly vent box to vent system of residual fuel pressure. Disconnect fitting once system is vented.
12. Disconnect upper tank rack wiring harness 8-pin connector and remove connector from bracket.






13. Remove front upper fuel tank rack assembly to body fasteners, located above the rear axle area.
14. Lower vehicle and remove two retaining nuts from the flexible tube retainer and position the fuel lines and wiring harness into luggage compartment.





15. Remove the rear upper fuel tank rack assembly to body bolts, located in the luggage compartment.

NOTE: Upper fuel tank rack assembly is installed with four retainers: two from underbody and two through luggage compartment area.










16. Remove upper fuel tank rack assembly from vehicle using Rotunda Powertrain Lift 014-00765 and Rotunda Fuel Tank Removal Bracket Set 014-00470 or equivalent.

WARNING: The Rotunda Fuel Tank Removal Bracket Set 014-00470 or equivalent must be secured to the upper fuel rack assembly with the retaining pins or possible damage to the vehicle or possible personal injury may occur.






17. Adjust Rotunda Fuel Tank Removal Bracket Set 014-00470 or equivalent to maintain clearance during removal of upper tank rack assembly.

CAUTION: Replace O-ring seal in the fittings. Lubricate O-rings with clean engine oil meeting Ford specification WSS-M2C153-F.

NOTE: Natural gas approved O-rings are identified with a yellow stripe. Do not use unapproved O-rings.

NOTE: Make sure all O-ring sealing surfaces are clean.