2009 Ford Flex SE

2009 ENGINE Fuel Tank & Lines - Flex

2009 ENGINE

Fuel Tank & Lines - Flex

SPECIFICATIONS
MATERIAL

MATERIAL SPECIFICATIONS
Fill
Item Specification
Capacity
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP
WSSM2C930-
(US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 -
A
(Canada); or equivalent

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS
Item Specification
Fuel tank capacity 70.41L (18.6 gal)

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS
Description Nm lb-ft lb-in
Fuel tank filler pipe bracket bolt 9 - 80
Fuel tank filler pipe hose clamp 3 - 27
Fuel tank strap bolts 35 26 -
Fuel tube bundle retainer bolt 20 - 177
Fuel tube bundle shield nut 9 - 80

DESCRIPTION AND OPERATION

FUEL TANK AND LINES

The fuel tank and lines consists of the:

 saddle-type fuel tank.

 Fuel Pump (FP) module.
 Easy Fuel ™ (capless) fuel tank filler pipe assembly.
 fuel level sensor assembly.
 fuel level sender (mounted on FP module and the fuel level sensor assembly).
 fuel tubes.
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 2009 Ford Flex SE
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 FP control module.
 Fuel Tank Pressure (FTP) sensor (part of the fuel vapor tube assembly).

The vehicle:

 uses a 2-speed Mechanical Returnless Fuel System (MRFS).

 has a dual-container (saddle-type) fuel tank.
 has a FP module that supplies fuel under pressure to the fuel rail.
 has a lifetime fuel filter (serviced as part of the FP module).
 has fuel tubes (liquid and vapor) along with brake tubes mounted on the underside of the vehicle in a
bundle.
 fuel injection rail pressure is controlled by the electronic FP module which is enabled by the PCM.
 has an Easy Fuel ™ (capless) fuel tank filler pipe assembly, which cannot be modified in any way and is
serviced only by installation of a new fuel tank filler pipe assembly.
 has a supplemental refueling adapter located in the spare tire compartment.
 has a FP module that operates on 10 or 12 volts depending on load, that supplies fuel under pressure to
the fuel rail.
 has a FP control module located behind the RH C-pillar trim panel.
 has a fuel level vent valve (part of the fuel tank FP module).
 has a serviceable fuel level sender mounted on the FP module and fuel level sensor assembly.

The FP is controlled by the PCM. Electrical power to the FP is provided through the FP control module.

DIAGNOSIS AND TESTING

FUEL TANK AND LINES

REFER to the INTRODUCTION - GASOLINE MODELS .

REMOVAL AND INSTALLATION

FUEL TANK AND FILLER PIPE - EXPLODED VIEW

Fuel Tank Filler Pipe Assembly

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 2009 Ford Flex SE
2009 ENGINE Fuel Tank & Lines - Flex

Fig. 1: Exploded View Of Fuel Tank Filler Pipe Assembly With Torque Specifications
Courtesy of FORD MOTOR CO.

PART DESCRIPTION CHART

Item Part Number Description
1 9K072A Fuel tank filler pipe information bezel
2 7828646 Fuel fill door cup
3 - Fuel tank filler pipe fresh air hose fitting (part of 9034)
4 9034 Fuel tank filler pipe assembly
5 W505254 Fuel tank filler pipe bracket bolt
6 - Fuel tank filler pipe fresh air hose (part of 9034)
7 - Fuel tank filler pipe hose (part of 9034)
8 - Fuel tank filler pipe recirculation tube (part of 9034)
9 W525936 Fuel tank filler pipe hose clamp

Fuel Tank Assembly

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 2009 Ford Flex SE
2009 ENGINE Fuel Tank & Lines - Flex

Fig. 2: Exploded View Of Fuel Tank Assembly With Torque Specifications

Courtesy of FORD MOTOR CO.

PART DESCRIPTION CHART

Item Part Description
Number
1 9C335 Fuel Pump (FP) module access cover
2 9C385 FP module lock ring
3 9H307 FP module
4 14A163 Fuel tank wire harness retainer (2 required)
5 14A464 Fuel tank wire harness electrical connector
6 - Evaporative Emission (EVAP) canister fresh air hose (part of 9S321)
7 - Internal fuel tube-to- FP module quick connect coupling (part of 9002)
8 9276 FP module O-ring seal

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 2009 Ford Flex SE
2009 ENGINE Fuel Tank & Lines - Flex

9 - Fuel tank jumper tube-to- FP module quick connect coupling (part of 9J337)
10 9055 RH fuel tank strap
11 W506433 Fuel tank strap bolt (4 required)
12 - Fuel vapor tube assembly-to-fuel tank filler pipe recirculation tube quick connect
coupling (part of 9C015)
13 14A464 FP module electrical connector
14 9002 Fuel tank
15 9C335 Fuel level sensor access cover
16 9C385 Fuel level sensor lock ring
17 9275 Fuel level sensor
18 - Internal fuel tube-to-fuel level sensor quick connect coupling (part of 9002)
19 9276 Fuel level sensor O-ring seal
20 - Fuel vapor tube-to-fuel level sensor quick connect coupling (part of 9P860)
21 14A464 Fuel level sensor electrical connector
22 - Fuel vapor tube assembly-to-fuel level sensor quick connect coupling (part of 9C047)
23 14407 Fuel tank jumper tube
24 9055 LH fuel tank strap

1. For additional information, refer to the procedures in this article.

FUEL TANK

Removal and Installation

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type
when working on or near any fuel related component. Highly flammable
mixtures are always present and may be ignited. Failure to follow these
instructions may result in serious personal injury.

WARNING: Do not carry personal electronic devices such as cell phones, pagers or
audio equipment of any type when working on or near any fuel-related
component. Highly flammable mixtures are always present and may be
ignited. Failure to follow these instructions may result in serious personal
injury.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system
components, relieve the fuel system pressure to prevent accidental
spraying of fuel. Fuel in the fuel system remains under high pressure,
even when the engine is not running. Failure to follow this instruction
may result in serious personal injury.

WARNING: When handling fuel, always observe fuel handling precautions and be
prepared in the event of fuel spillage. Spilled fuel may be ignited by hot
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 2009 Ford Flex SE
2009 ENGINE Fuel Tank & Lines - Flex

vehicle components or other ignition sources. Failure to follow these

instructions may result in serious personal injury.

WARNING: Always disconnect the battery ground cable at the battery when working
on an evaporative emission (EVAP) system or fuel-related component.
Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in serious personal injury.

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING &
LIFTING .
2. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING
AND CABLES .
3. Drain the fuel tank. For additional information, refer to FUEL SYSTEM - GENERAL
INFORMATION .
4. Remove the muffler and tailpipe. For additional information, refer to EXHAUST SYSTEM .

All-Wheel Drive (AWD) vehicles

5. Remove the driveshaft. For additional information, refer to DRIVESHAFT .

All vehicles

NOTE: Some residual fuel may remain in the fuel tank filler pipe after draining the
fuel tank. Carefully drain any residual fuel into a suitable container.

6. Release the clamp and remove the fuel tank filler pipe hose from the fuel tank.
 To install, tighten to 3 Nm (27 lb-in).

7. Disconnect the Evaporative Emission (EVAP) canister fresh air hose from the fuel tank filler pipe fresh
air hose.
8. Disconnect the fuel vapor tube assembly-to-fuel tank filler pipe recirculation tube quick connect coupling.
For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
9. Disconnect the fuel tank jumper tube-to-fuel tube quick connect coupling. For additional information,
refer to FUEL SYSTEM - GENERAL INFORMATION .
10. Remove the EVAP canister. For additional information, refer to EVAPORATIVE EMISSIONS .
11. Position a suitable lifting device under the fuel tank.
12. Loosen the 2 rear fuel tank strap bolts.
 Calculate the correct torque wrench setting for the following torque using the equations in the
following illustration.

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 2009 Ford Flex SE
2009 ENGINE Fuel Tank & Lines - Flex

Fig. 3: Torque Wrench Adapter Formulas

Courtesy of FORD MOTOR CO.

To install, use a torque adapter and tighten to 35 Nm (26 lb-ft).



13. Remove the 2 front fuel tank strap bolts.

 To install, tighten to 35 Nm (26 lb-ft).

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 2009 Ford Flex SE
2009 ENGINE Fuel Tank & Lines - Flex

NOTE: Do not bend or distort the fuel tank straps.

14. Release the 2 straps from the fuel tank and carefully position aside.
15. Partially lower the fuel tank enough to allow access to the fuel tank wire to the main body wiring harness
electrical connector.
16. Release the 2 wire harness retainers and disconnect the fuel tank wire to the main body wire harness
electrical connector.
17. Completely lower and remove the fuel tank from the vehicle.
18. To install, reverse the removal procedure.

FUEL TANK FILLER PIPE

Removal and Installation

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type
when working on or near any fuel-related component. Highly flammable
mixtures are always present and may be ignited. Failure to follow these
instructions may result in serious personal injury.

WARNING: Do not carry personal electronic devices such as cell phones, pagers or
audio equipment of any type when working on or near any fuel-related
component. Highly flammable mixtures are always present and may be
ignited. Failure to follow these instructions may result in serious personal
injury.

WARNING: When handling fuel, always observe fuel handling precautions and be
prepared in the event of fuel spillage. Spilled fuel may be ignited by hot
vehicle components or other ignition sources. Failure to follow these
instructions may result in serious personal injury.

WARNING: Always disconnect the battery ground cable at the battery when working
on an evaporative emission (EVAP) system or fuel-related component.
Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in serious personal injury.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING &
LIFTING .
2. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING
AND CABLES .
3. Remove the RH rear wheel and tire. For additional information, refer to WHEELS & TIRES .
4. Remove the 3 screws, 3 pushpins, 7 scrivets and the RH rear fender splash shield.

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 2009 Ford Flex SE
2009 ENGINE Fuel Tank & Lines - Flex

Fig. 4: Locating Rear Fender Splash Shield With Screws And Pushpins, Scrivets (RH)
Courtesy of FORD MOTOR CO.

NOTE: Some residual fuel may remain in the fuel tank filler pipe. Carefully drain
into a suitable container.

5. Release the clamp and remove the fuel tank filler pipe hose from the fuel tank.
 To install, tighten to 3 Nm (27 lb-in).

6. Disconnect the Evaporative Emission (EVAP) canister fresh air hose from the fuel tank filler pipe fresh
air hose.
7. Disconnect the fuel vapor tube assembly-to-fuel tank filler pipe recirculation tube quick connect coupling.
For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
8. Remove the fuel tank filler pipe bracket bolt.
 To install, tighten to 9 Nm (80 lb-in).

9. Disconnect the fuel tank filler pipe fresh air hose from the fuel fill door cup bezel.
10. Remove the fuel tank filler pipe information bezel.
11. Remove the fuel tank filler pipe assembly.
12. To install, reverse the removal procedure.

FUEL PUMP MODULE

Special Tool(s)

SPECIAL TOOLS CHART

Fuel Storage Tanker

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 2009 Ford Flex SE
2009 ENGINE Fuel Tank & Lines - Flex

164-R3202 or equivalent

Wrench, Fuel Tank Sender Unit

310-123

Material

MATERIAL SPECIFICATIONS
Item Specification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil
WSSM2C930-
XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-
A
LSP12 (Canada); or equivalent
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 2009 Ford Flex SE
2009 ENGINE Fuel Tank & Lines - Flex

Removal and Installation

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type
when working on or near any fuel-related component. Highly flammable
mixtures are always present and may be ignited. Failure to follow these
instructions may result in serious personal injury.

WARNING: Do not carry personal electronic devices such as cell phones, pagers or
audio equipment of any type when working on or near any fuel-related
component. Highly flammable mixtures are always present and may be
ignited. Failure to follow these instructions may result in serious personal
injury.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system
components, relieve the fuel system pressure to prevent accidental
spraying of fuel. Fuel in the fuel system remains under high pressure,
even when the engine is not running. Failure to follow this instruction
may result in serious personal injury.

WARNING: When handling fuel, always observe fuel handling precautions and be
prepared in the event of fuel spillage. Spilled fuel may be ignited by hot
vehicle components or other ignition sources. Failure to follow these
instructions may result in serious personal injury.

WARNING: Always disconnect the battery ground cable at the battery when working
on an evaporative emission (EVAP) system or fuel-related component.
Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in serious personal injury.

NOTE: The Fuel Pump (FP) module has a serviceable fuel level sender. For additional
information, refer to FUEL LEVEL SENDER.

1. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL
INFORMATION .
2. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING
AND CABLES .
3. Remove the FP module access cover.

NOTE: Clean the FP module connections, couplings, flange surfaces and the
immediate surrounding area of any dirt or foreign material.

4. Disconnect the FP module electrical connector.

NOTE: Place absorbent toweling in the immediate surrounding area in case of

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 2009 Ford Flex SE
2009 ENGINE Fuel Tank & Lines - Flex

fuel spillage.

5. Disconnect the fuel tank jumper tube-to- FP module quick connect coupling. For additional information,
refer to FUEL SYSTEM - GENERAL INFORMATION .
6. Connect the Fuel Storage Tanker to the FP module outlet fitting and remove approximately one-fourth of
the fuel (from a completely full tank), lowering the fuel level below the FP module mounting flange.

Fig. 5: Locating FP Module Outlet Fitting

Courtesy of FORD MOTOR CO.

NOTE: Carefully install the Fuel Tank Sender Unit Wrench to avoid damaging the
FP module when removing the lock ring.

7. Using the Fuel Tank Sender Unit Wrench, remove the FP module lock ring.
 Discard the FP module lock ring.

Fig. 6: Removing FP Module Lock Ring

Courtesy of FORD MOTOR CO.

NOTE: The Fuel Pump (FP) module must be handled carefully to avoid damage to
the float arm.

8. Carefully lift the FP module out of the fuel tank allowing access and disconnect the internal fuel tube-to-
FP module quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL
INFORMATION .

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 2009 Ford Flex SE
2009 ENGINE Fuel Tank & Lines - Flex

NOTE: Some residual fuel may remain in the FP module. Carefully drain into a
suitable container.

9. Completely remove the FP module from the fuel tank.

NOTE: Inspect the surfaces of the FP module flange and fuel tank O-ring seal
contact surfaces. Do not polish or adjust the O-ring seal contact area of
the fuel tank flange or the fuel tank. Install a new FP module or fuel tank if
the O-ring seal contact area is bent, scratched or corroded.

NOTE: To install, apply clean engine oil to the O-ring seal.

10. Remove and discard the FP module O-ring seal.

NOTE: Make sure to install a new FP module O-ring seal and lock ring.

11. To install, reverse the removal procedure.

 Make sure the alignment arrows on the FP module and the fuel tank meet before tightening the FP
module lock ring.
 Tighten the FP lock ring until it meets the stop tabs on the fuel tank.

FUEL LEVEL SENSOR

Special Tool(s)

SPECIAL TOOLS CHART

Fuel Storage Tanker

164-R3202 or equivalent

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 2009 Ford Flex SE
2009 ENGINE Fuel Tank & Lines - Flex

Wrench, Fuel Tank Sender Unit

310-123

Material

MATERIAL SPECIFICATIONS
Item Specification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil
WSSM2C930-
XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-
A
LSP12 (Canada); or equivalent

Removal and Installation

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type
when working on or near any fuel-related component. Highly flammable
mixtures are always present and may be ignited. Failure to follow these
instructions may result in serious personal injury.

WARNING: Do not carry personal electronic devices such as cell phones, pagers or
audio equipment of any type when working on or near any fuel-related
component. Highly flammable mixtures are always present and may be
ignited. Failure to follow these instructions may result in serious personal
injury.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system
components, relieve the fuel system pressure to prevent accidental
spraying of fuel. Fuel in the fuel system remains under high pressure,
even when the engine is not running. Failure to follow this instruction

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 2009 Ford Flex SE
2009 ENGINE Fuel Tank & Lines - Flex

may result in serious personal injury.

WARNING: When handling fuel, always observe fuel handling precautions and be
prepared in the event of fuel spillage. Spilled fuel may be ignited by hot
vehicle components or other ignition sources. Failure to follow these
instructions may result in serious personal injury.

WARNING: Always disconnect the battery ground cable at the battery when working
on an evaporative emission (EVAP) system or fuel-related component.
Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in serious personal injury.

NOTE: The fuel level sensor has a serviceable fuel level sender. For additional
information, refer to FUEL LEVEL SENDER.

1. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL
INFORMATION .
2. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING
AND CABLES .
3. Remove the Fuel Pump (FP) module access cover.

NOTE: Clean the FP module connections, couplings, flange surfaces and the
immediate surrounding area of any dirt or foreign material.

4. Disconnect the FP module electrical connector.

NOTE: Place absorbent toweling in the immediate surrounding area in case of

fuel spillage.

5. Disconnect the fuel tank jumper tube-to- FP module quick connect coupling. For additional information,
refer to FUEL SYSTEM - GENERAL INFORMATION .
6. Connect the Fuel Storage Tanker to the FP module outlet fitting and remove approximately one-fourth of
the fuel (from a completely full tank), lowering the fuel level below the fuel level sensor mounting flange.

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 2009 Ford Flex SE
2009 ENGINE Fuel Tank & Lines - Flex

Fig. 7: Locating FP Module Outlet Fitting

Courtesy of FORD MOTOR CO.

7. Remove the fuel level sensor access cover.

NOTE: Clean the fuel level sensor connections, couplings, flange surfaces and
the immediate surrounding area of any dirt or foreign material.

8. Disconnect the fuel level sensor electrical connector.

9. Disconnect the fuel vapor tube assembly-to-fuel level sensor quick connect coupling. For additional
information, refer to FUEL SYSTEM - GENERAL INFORMATION .
10. Disconnect the fuel vapor tube-to-fuel level sensor quick connect coupling. For additional information,
refer to FUEL SYSTEM - GENERAL INFORMATION .

NOTE: Place absorbent toweling in the immediate surrounding area in case of

fuel spillage.

NOTE: Carefully install the Fuel Tank Sender Unit Wrench to avoid damaging the
fuel level sensor when removing the lock ring.

11. Using the Fuel Tank Sender Unit Wrench, remove the fuel level sensor lock ring.
 Discard the fuel level sensor lock ring.

Fig. 8: Removing Fuel Level Sensor Lock Ring

Courtesy of FORD MOTOR CO.

NOTE: The fuel level sensor must be handled carefully to avoid damage to the
float arm.

12. Carefully lift the fuel level sensor out of the fuel tank allowing access and disconnect the internal fuel
tube-to-fuel level sensor quick connect coupling. For additional information, refer to FUEL SYSTEM -
GENERAL INFORMATION .

NOTE: Some residual fuel may remain in the fuel level sensor. Carefully drain into

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 2009 Ford Flex SE
2009 ENGINE Fuel Tank & Lines - Flex

a suitable container.

13. Remove the fuel level sensor from the fuel tank.

NOTE: Upon installation, apply clean engine oil to the O-ring seal.

14. Remove and discard the fuel level sensor O-ring seal.

NOTE: Make sure to install a new fuel level sensor lock ring and O-ring seal.

15. To install, reverse the removal procedure.

 Make sure the alignment arrows on the fuel level sensor and the fuel tank meet before tightening
the fuel level sensor lock ring.
 Tighten the fuel level sensor lock ring until it meets the stop tabs on the fuel tank.

FUEL LEVEL SENDER

Fuel Pump (FP) Module Mounted Sender

Fig. 9: Identifying Fuel Pump (FP) Module Mounted Sender Components

Courtesy of FORD MOTOR CO.

PART DESCRIPTION CHART

Item Part Number Description
1 9H307 Fuel Pump (FP) module
2 9A299 Fuel level sender
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 2009 Ford Flex SE
2009 ENGINE Fuel Tank & Lines - Flex

3 - Fuel level sender electrical connector (part of 9A299)

Fuel Level Sensor Assembly Mounted Sender

Fig. 10: Identifying Fuel Level Sensor Assembly Mounted Sender Components
Courtesy of FORD MOTOR CO.

PART DESCRIPTION CHART

Item Part Number Description
1 9275A Fuel level sensor assembly
2 9A299 Fuel level sender
3 - Fuel level sender electrical connector (part of 9A299)

Removal and Installation

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type
when working on or near any fuel-related component. Highly flammable
mixtures are always present and may be ignited. Failure to follow these
instructions may result in serious personal injury.

WARNING: Do not carry personal electronic devices such as cell phones, pagers or
audio equipment of any type when working on or near any fuel-related
component. Highly flammable mixtures are always present and may be
ignited. Failure to follow these instructions may result in serious personal
injury.
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 2009 Ford Flex SE
2009 ENGINE Fuel Tank & Lines - Flex

WARNING: When handling fuel, always observe fuel handling precautions and be
prepared in the event of fuel spillage. Spilled fuel may be ignited by hot
vehicle components or other ignition sources. Failure to follow these
instructions may result in serious personal injury.

WARNING: Always disconnect the battery ground cable at the battery when working
on an evaporative emission (EVAP) system or fuel-related component.
Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in serious personal injury.

1. Remove either the Fuel Pump (FP) module or fuel level sensor assembly. For additional information,
refer to FUEL PUMP MODULE or FUEL LEVEL SENSOR.
2. Disconnect the fuel level sender electrical connector.
3. Depress the lock tab and slide the fuel level sender upwards and remove.

Fig. 11: Sliding Fuel Level Sender Upwards

Courtesy of FORD MOTOR CO.

4. To install, reverse the removal procedure.

FUEL LINES

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 2009 Ford Flex SE
2009 ENGINE Fuel Tank & Lines - Flex

Fig. 12: Identifying Fuel Lines Components With Torque Specifications

Courtesy of FORD MOTOR CO.

PART DESCRIPTION CHART

Item Part Description
Number
1 - Fuel supply tube-to-fuel rail jumper tube quick connect coupling (part of 9G700)
2 9G641 Evaporative Emission (EVAP) canister purge valve
3 - Fuel supply tube (part of 9G700)
4 - Fuel vapor tube-to- EVAP canister purge valve quick connect coupling (part of
9G700)
5 W713916 Fuel tube bundle retainer stud and nut
6 - Fuel tube bundle retainer (part of 9G700)
7 - Fuel vapor tube (part of 9G700)
8 - Fuel tube bundle separator (part of 9G700)
9 9G700 Fuel tube bundle shield
10 - Fuel vapor tube-to- EVAP canister quick connect coupling (part of 9G700)
11 - Fuel supply tube-to-fuel tank jumper tube quick connect coupling (part of 9G700)
12 W711059 Fuel tube bundle shield nut
13 W711059 EVAP canister shield nut
14 - EVAP canister shield (part of 9E857)
15 - Fuel tube bundle separator (part of 9G700)

Removal and Installation

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 2009 Ford Flex SE
2009 ENGINE Fuel Tank & Lines - Flex

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type
when working on or near any fuel-related component. Highly flammable
mixtures are always present and may be ignited. Failure to follow these
instructions may result in serious personal injury.

WARNING: Do not carry personal electronic devices such as cell phones, pagers or
audio equipment of any type when working on or near any fuel-related
component. Highly flammable mixtures are always present and may be
ignited. Failure to follow these instructions may result in serious personal
injury.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system
components, relieve the fuel system pressure to prevent accidental
spraying of fuel. Fuel in the fuel system remains under high pressure,
even when the engine is not running. Failure to follow this instruction
may result in serious personal injury.

WARNING: When handling fuel, always observe fuel handling precautions and be
prepared in the event of fuel spillage. Spilled fuel may be ignited by hot
vehicle components or other ignition sources. Failure to follow these
instructions may result in serious personal injury.

WARNING: Always disconnect the battery ground cable at the battery when working
on an evaporative emission (EVAP) system or fuel-related component.
Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in serious personal injury.

1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING &
LIFTING .
2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL
INFORMATION .

NOTE: Some residual fuel may remain in the fuel tubes after releasing the fuel
system pressure. Upon disconnecting or removing any fuel tubes,
carefully drain any residual fuel into a suitable container.

3. Disconnect the fuel supply tube-to-fuel rail jumper tube quick connect coupling. For additional
information, refer to FUEL SYSTEM - GENERAL INFORMATION .
4. Disconnect the fuel vapor tube-to-Evaporative Emission (EVAP) canister purge valve quick connect
coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
5. Remove the nut from the stud and release the fuel tubes from the bundle retainer.
 To install, tighten to 20 Nm (177 lb-in).

6. Disconnect the fuel vapor tube-to- EVAP canister quick connect coupling. For additional information,
refer to FUEL SYSTEM - GENERAL INFORMATION .
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 2009 Ford Flex SE
2009 ENGINE Fuel Tank & Lines - Flex

7. Disconnect the fuel supply tube-to-fuel tank jumper tube quick connect coupling. For additional
information, refer to FUEL SYSTEM - GENERAL INFORMATION .
8. Remove the nut and position the EVAP canister shield aside.
 To install, tighten to 9 Nm (80 lb-in).

9. Remove the fuel tube bundle shield nut.

 To install, tighten to 9 Nm (80 lb-in).

10. Release the fuel tube bundle separators.

11. Release the fuel tubes from the fuel tube bundle shield and remove the tubes.
12. To install, reverse the removal procedure.

Microsoft
Thursday, April 22, 2010 6:49:55 AM Page 22 © 2006 Mitchell Repair Information Company, LLC.