2003 Taurus Gas Tank Removal

The 2003 Ford Taurus was equipped with a 3.0-liter EFI V-6 engine in the base model. The two optional engines in the 2003 Taurus were a 3.0-liter EFI DOHC V-6, and a 3.0-liter Flex-Fuel V-6. The rear-mounted fuel tank on the 2003 Taurus may have to be removed to replace the tank, the fuel pump or other portions of the fuel system near the fuel tank. Accessing and removing the fuel tank requires close attention to detail, due to the high flammability precautions needed during this project.

Instructions

1

Open the hood of the Taurus. Disconnect the negative battery cable from the battery with a ratchet and socket. Tuck the cable to the side of the battery, so there is no chance of accidental contact during this project. Remove the cap from the fuel pressure tester port on the fuel rail. Wrap a rag or towel around the tip of a screwdriver. Insert the screwdriver and rag into the pressure port and depress the pin in the center of the port. Allow the fuel to soak into the rag as the pressure is relieved from the fuel system.

2

Open the fuel door and remove the fuel filler cap from the filler neck. This will allow excess fuel vapors and fumes to escape while you remove the fuel tank. Raise the rear of the Taurus with a jack. Place jack stands beneath the rear axle beam that extends between the two rear wheels. Lower the car onto the jack stands.

3

Place a plank of wood on top of your floor jack. Raise the floor jack and wood plank to the bottom of the fuel tank. Place a pair of flat-nose locking pliers around the rubber fuel filler hose behind the fuel tank. Remove the fuel tank strap bolts with a ratchet and socket. Lower the straps and move them to the side of the tank. Remove fuel pump electrical connector by hand.

4

Lower the fuel tank halfway between the car and the ground, using the jack and the plank of wood. Loosen the hose clamps from the small hoses on the fuel pump assembly and the fuel filler hose, with a ratchet and socket. Remove the hoses from the tank and pump. Remove the fuel tank tubes by disconnecting the three quick disconnect couplings.

5

Lower the fuel tank to the ground, and rest it onto a large piece of cardboard. Slide the tank out from beneath the car, on the cardboard.

6

If you are not reusing the old fuel pump, proceed to Step 7. Remove the fuel pump lock ring from the top of the fuel tank by placing a flat-head screwdriver against the vertical tab on the lock ring. Tap the lock ring counterclockwise with a hammer to unlock it from the fuel tank. Pull the fuel tank ring off of the fuel pump assembly. Remove the fuel pump from the tank, and transfer it to your new tank, making sure the pump enters the new tank in the same direction it was removed from the old one.

7

Install the fuel pump, gasket and lock ring onto the fuel tank. Make sure the gasket is between the lock ring and the lip of the tank. Press the lock ring down by hand, and rotate it clockwise to make sure the tabs on the lock ring line up with the tabs on the fuel tank. Insert a flat-head screwdriver against the vertical tab on the lock ring. Tap the lock ring clockwise to lock it onto the fuel tank completely.

8

Set the fuel tank onto the large piece of cardboard. Slide the fuel tank on the cardboard beneath the car. Set the fuel tank onto the jack and plank of wood. Raise the fuel tank halfway between the bottom of the car and ground. You can slide the fuel tank straps beneath the tank to help balance it at this point, if needed.

9

Install the fuel tubes onto the fuel tank. Tighten any hose clamps snug with a ratchet and socket. Install the fuel pump electrical connector onto the fuel pump by hand. Raise the tank up to the bottom of the car, but do not push up on the bottom of the fuel tank with the jack.

10

Install the fuel tank straps around the fuel tank, and install the tank strap bolts by hand to ensure proper initial threading. Tighten the fuel tank straps to 26 foot-pounds of torque with a 1/2-inch-drive torque wrench and socket. Remove the locking pliers from the fuel filler hose.

11

Position yourself in front of the Taurus at the engine compartment. Install the negative battery cable, and tighten it snug with your ratchet and socket.