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Fuel Additive System Module > < Fuel Tank - 1.6L Duratorq-TDCi (DV) Diesel-2.0L Duratorq-TDCi (DW) Diesel, Vehicles With: Fuel Additive Tank
Fuel Tank and Lines - Fuel Tank—1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Vehicles Without: Fuel Additive Tank C-MAX 2003.75 (06/2003-)
Removal and Installation

Special Tool(s)

Wrench, Fuel Tank Sender Unit

(310-069) 23-055

General Equipment
Transmission jack
WARNING:
WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.
WARNING:
WARNING:This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury.
  1. Drain the fuel tank.
    For additional information, refer to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures).
  1. Raise and support the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. Detach the exhaust system from the middle hanger insulator.

  1. Remove the exhaust flange nuts.
    • Discard the gasket and exhaust flange retaining nuts.

  1. NOTE:
    NOTE:With the aid of another technician support the exhaust.
    Detach the exhaust system from the front hanger insulators.

  1. Position the exhaust to one side and secure to the body with tie-straps.

7. Remove the components in the order indicated in the following illustration(s) and table(s).

 
Item
Part Number
Description
1
-
Exhaust pipe center heat shield retaining bolts
2
-
Fuel tank heat shield

 
Item
Part Number
Description
4
-
Fuel tank filler hose
See Removal Detail
5
-
Fuel tank vent hose retaining clamp
See Removal Detail
See Installation Detail
6
-
Fuel tank vent hose
See Removal Detail
7
-
Fuel tank fuel return line quick release coupling
See Removal Detail
8
-
Fuel tank fuel supply line quick release coupling
See Removal Detail
9
-
11
-
Fuel tank module electrical connector
See Removal Detail
See Installation Detail

 
Item
Part Number
Description
13
-
Fuel tank vent hose
See Removal Detail
14
-
Fuel tank fuel return line quick release coupling
See Removal Detail
15
-
Fuel tank fuel supply line quick release coupling
See Removal Detail
16
-
Fuel tank module locking ring
See Removal Detail
See Installation Detail
18
-
Fuel tank module seal
19
-
fuel tank

8. To install, reverse the removal procedure.

  1. Initialize the door window motors.
    For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).

Removal Details

Item 3 : Fuel tank filler hose retaining clamps

  1. NOTE:
    NOTE:Make a note of the position of the fuel tank filler hose retaining clamp. Make sure that the new replacement screw type clamp is positioned so that the screw head is in the same position as as the original filler hose retaining clamp.
    Remove and discard the fuel tank filler hose retaining clamp.

  1. NOTE:
    NOTE:Make a note of the position of the fuel tank filler hose retaining clamp. Make sure that the new replacement screw type clamp is positioned so that the screw head is in the same position as as the original filler hose retaining clamp.
    Remove and discard the fuel tank filler hose retaining clamp (rear sub-frame shown removed for clarity).

Item 4 : Fuel tank filler hose

  1. CAUTION:
    CAUTION:When removing the fuel tank filler hose, do not use any sharp edge tools to lever off the pipes. Failure to follow this instruction may result in damage to the filler hose.
    Remove the fuel tank filler hose.

Item 5 : Fuel tank vent hose retaining clamp

  1. NOTE:
    NOTE:Make a note of the position of the fuel tank vent hose retaining clamp. Make sure that the new replacement screw type clamp is positioned so that the screw head is in the same position as as the original vent hose retaining clamp.
    Remove and discard the fuel tank vent hose retaining clamp (rear sub-frame shown removed for clarity).

Item 6 : Fuel tank vent hose

  1. CAUTION:
    CAUTION:When removing the fuel tank vent hose, do not use any sharp edge tools to lever off the pipes. Failure to follow this instruction may result in damage to the vent hose.
    Disconnect the fuel tank vent hose from the fuel tank filler pipe.

Item 7 : Fuel tank fuel return line quick release coupling

  1. Disconnect the fuel tank fuel return line spring lock coupling.
    For additional information, refer to: Spring Lock Couplings (310-00 Fuel System - General Information, General Procedures).

Item 8 : Fuel tank fuel supply line quick release coupling

  1. Disconnect the fuel tank fuel supply line quick release coupling.
    For additional information, refer to: Spring Lock Couplings (310-00 Fuel System - General Information, General Procedures).

Item 9 : Fuel tank support straps

CAUTION:
CAUTION:When supporting the fuel tank, use a suitable packing material to prevent damage to the underside of the fuel tank.

  1. Place a suitable transmission jack under the fuel tank.

Item 10 : Fuel Tank

CAUTION:
CAUTION:When lowering the fuel tank, do not place excessive strain on the fuel lines and wiring harness.
  1. Partially lower the fuel tank.

Item 11 : Fuel tank module electrical connector

  1. Disconnect the fuel tank module electrical connector.

Item 12 : Fuel tank vent hose retaining clamp

  1. NOTE:
    NOTE:Make a note of the position of the fuel tank vent hose retaining clamp. Make sure that the new replacement screw type clamp is positioned so that the screw head is in the same position as as the original vent hose retaining clamp.
    Remove and discard the fuel tank vent hose retaining clamp.

Item 13 : Fuel tank vent hose

  1. CAUTION:
    CAUTION:When removing the fuel tank vent hose, do not use any sharp edge tools to lever off the pipes. Failure to follow this instruction may result in damage to the vent hose.
    Remove the fuel tank vent hose from the fuel tank.

Item 14 : Fuel tank fuel return line quick release coupling

  1. Disconnect the fuel tank fuel return line quick release coupling.
    For additional information, refer to: Spring Lock Couplings (310-00 Fuel System - General Information, General Procedures).

Item 15 : Fuel tank fuel supply line quick release coupling

  1. Disconnect the fuel tank fuel supply line quick release coupling.
    For additional information, refer to: Spring Lock Couplings (310-00 Fuel System - General Information, General Procedures).

Item 16 : Fuel tank module locking ring

  1. Using the special tool, remove the fuel tank locking ring.

Item 17 : Fuel tank module

CAUTION:
CAUTION:Make sure the fuel tank level sensor float and arm are not damaged during the removal of the fuel tank module.

Installation Details

Item 17 : Fuel tank module

  1. CAUTION:
    CAUTION:Make sure the fuel tank level sensor float and arm are not damaged during the installation of the fuel tank module.
    Make sure the arrows on the fuel tank and fuel tank module are aligned correctly.

Item 16 : Fuel tank module locking ring

  1. Using the special tool, install the fuel tank locking ring.

Item 12 : Fuel tank vent hose retaining clamp

  1. Install a new fuel tank vent hose retaining clamp in the position shown.

Item 10 : Fuel Tank

CAUTION:
CAUTION:When installing the fuel tank, make sure the fuel lines do not get kinked or trapped.
  1. Partially raise the fuel tank.

Item 11 : Fuel tank module electrical connector

  1. Connect the fuel tank module electrical connector.

Item 9 : Fuel tank support straps

  1. Install the fuel tank support strap retaining bolts and remove the transmission jack.

Item 5 : Fuel tank vent hose retaining clamp

  1. Install a new fuel tank filler hose retaining clamp in the position shown (rear sub-frame shown removed for clarity).

Item 3 : Fuel tank filler hose retaining clamps

  1. Install a new fuel tank filler hose retaining clamp in the position shown.

  1. Install a new fuel tank filler hose retaining clamp in the position shown (rear sub-frame shown removed for clarity).

Fuel Additive System Module > < Fuel Tank - 1.6L Duratorq-TDCi (DV) Diesel-2.0L Duratorq-TDCi (DW) Diesel, Vehicles With: Fuel Additive Tank