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Inertia Fuel Shutoff (IFS) Switch - Vehicles Built From: 12-2004 > < Fuel Tank - Vehicles Built From: 11-2003

Maverick 2005 (08.2004-)

Fuel Tank and Lines - Fuel Tank Filler Pipe—Vehicles Built From: 11/2003 Maverick 2005 (08/2004-)
Removal and Installation

Special Tool(s)

Heavy Duty Riveter

D80-23200-A or equivalent
Materials
Name
Specification
SAE 5W-20 Motorcraft Premium Synthetic Blend Motor Oil
XO-5W20-QSP
WSS-M2C930-A

Removal

WARNING:
WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury.
WARNING:
WARNING:The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery ground cable from the battery to minimize the possibility of an electrical spark occurring, and possibly causing a fire or explosion if fuel vapor or liquid fuel are present in the area. Failure to follow these instructions can result in personal injury.
WARNING:
WARNING:Fuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel causing personal injury or a fire hazard.
WARNING:
WARNING:The fuel in the tank may be pressurized. Remove the fuel tank cap slowly. If a hissing sound is heard, wait until the condition stops before removing the fuel tank filler cap. If these precautions are not followed, fuel may spray and cause personal injury.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02 Jacking and Lifting.
  1. Release the fuel system pressure. For additional information, refer to Section 310-00 Fuel System - General Information.
  1. Disconnect the battery ground cable. For additional information, refer to Section 414-01 Battery, Mounting and Cables.
  1. Remove the 2 fuel filler pipe mounting screws.
  1. Remove the rivets and the fuel tank tube shield.
  1. Remove the fuel filler pipe mounting screw.

  1. CAUTION:
    CAUTION:When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating the tube.
    NOTE:
    NOTE:If the vapor tube or retainer clip is broken or damaged, install a suitable fuel tube disconnect tool to separate the retainer clip legs. Once the retainer clip legs have separated, lift the clip out of the connector housing, lifting the stamped side of the connector body.
    Disconnect the fuel vapor tube quick release coupling from the fuel tank filler tube.
    1. Push the connector toward the tube to release the pressure.
    1. Press the fuel vapor tube quick release coupling button and pull the vapor tube to disconnect.
  1. Detach the fuel vapor vent hose retainer clip from the fuel tank flange.
  1. Disconnect the fuel vapor vent hose from the evaporative emissions canister.
  1. Reposition the clamp and disconnect the fuel filler pipe hose from the fuel tank.
    • Remove the fuel tank filler pipe as a complete assembly.

Installation

  1. Position the fuel tank filler pipe assembly in the vehicle.
    • Install the fuel filler pipe hose and clamp onto the fuel tank.
  1. Connect the fuel vapor vent hose to the evaporative emissions canister.
  1. Attach the fuel vapor vent hose retainer clip to the fuel tank flange.

  1. CAUTION:
    CAUTION:Make sure the vapor tube clicks into place when installing the tube. To make sure the tube is fully seated, pull on the tube.
    NOTE:
    NOTE:Apply clean engine oil to the end of the tube before inserting the tube into the connector.
    Connect the fuel vapor tube quick release coupling onto the fuel tank filler tube.
  1. Install the fuel filler pipe mounting screw.
    • To install, tighten to 10 Nm (89 lb-in).
  1. Install the fuel tank tube shield with new rivets.
  1. Install the 2 fuel filler pipe mounting screws.
    • To install, tighten to 5 Nm (42 lb-in).
  1. Turn the ignition key to the ON position to pressurize the fuel system.
  1. Visually inspect the fuel system for leaks.

Inertia Fuel Shutoff (IFS) Switch - Vehicles Built From: 12-2004 > < Fuel Tank - Vehicles Built From: 11-2003