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Removal and Installation

WARNING: This page is about a different car, the 2005 Mercury Montego, 2005 Ford Freestyle, and 2005 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Removing Fuel Level Sensor
G03992105Courtesy of FORD MOTOR CO.
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. Failure to follow these instructions can result in 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 components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.
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.

    All Vehicles 

  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 .
  3. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  4. Remove the fuel tank filler cap.
  5. Insert a suitable fuel drain tube into the fuel tank filler pipe until it reaches the fuel tank inlet spout.
    Fig 2: Inserting Suitable Fuel Drain Hose Into Fuel Tank Filler Pipe
    G03986097Courtesy of FORD MOTOR CO.
    6. NOTE: When the fuel tank is completely full, this step will remove approximately l/8th of fuel from the fuel tank.
  6. Attach the fuel storage tanker to the fuel drain tube and remove any residual fuel in the fuel tank filler pipe.
    7. CAUTION: The fuel pump module, fuel level sensor and the fuel tank inlet spout are below the fuel level in the fuel tank when the fuel tank is completely filled. Make sure to drain any residual fuel from the fuel tank filler pipe prior to removing the fuel tank filler pipe clamp and hose.
    Fig 3: Removing Clamp Screw Of Fuel Tank Filler Pipe Hose
    G03992107Courtesy of FORD MOTOR CO.
  7. Release the clamp and remove the fuel tank filler pipe hose from the fuel tank inlet spout.
  8. Insert a suitable fuel drain tube into the fuel tank inlet spout.
    Fig 4: Inserting Suitable Fuel Drain Tube Into Fuel Tank Inlet Spout
    G03992081Courtesy of FORD MOTOR CO.
    9. NOTE: When draining a completely full fuel tank, this step will drain most of the fuel from the RH side of the fuel tank and partially drain the LH side of the fuel tank due to the siphoning effect from the fuel crossover tube.
  9. Attach the fuel storage tanker to the fuel drain tube and drain the fuel from the RH side of the fuel tank.

    10. Five Hundred, Montego 

  10. Remove the rear lower seat cushion.
    • Release the latches and pull upward on the rear lower seat cushion and remove.
      Fig 5: Identifying Lower Seat Cushion Releasing Latch
      G03945904Courtesy of FORD MOTOR CO.

    11. Freestyle 

  11. Position the second row seat forward.
  12. Remove the bolt and the LH third row rear seat load floor support.
    • To install, tighten to 17 Nm (13 lb-ft).
  13. Remove the LH second row seat belt anchor bolt.
    • To install, tighten to 30 Nm (20 lb-ft).

    14. All vehicles 

  14. Position any carpet and/or insulation covering the fuel level sensor access cover aside.
  15. Remove the fuel level sensor access cover.
  16. Clean the surrounding area of the fuel level sensor mounting flange.
  17. Disconnect the fuel level sensor electrical connector.
  18. Install the special tool and remove the fuel level sensor lock ring.
    Fig 6: Removing Fuel Level Sensor Lock Ring
    G03992082Courtesy of FORD MOTOR CO.
  19. Carefully lift the fuel level sensor out of the fuel tank allowing access to disconnect the quick connect coupling.
  20. Disconnect the fuel supply tube-to-fuel level sensor quick connect coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
    21. CAUTION: The fuel level sensor must be handled carefully to avoid damage to the float arm.
    CAUTION: Place absorbant pads on the floor pan in case of spills. Carefully remove fuel level sensor from the fuel tank to avoid fuel spillage inside the vehicle.
  21. Completely remove the fuel level sensor from the fuel tank.
    22. CAUTION: Inspect the surfaces of the fuel level sensor module flange and the fuel tank. Install a new fuel level sensor or fuel tank if the O-ring seal contact surfaces are bent, scratched or corroded. Do not polish or adjust the module or fuel tank if the O-ring seal contact area is bent, scratched or corroded.
    CAUTION: Make sure to install a new fuel level sensor O-ring seal and lock ring.
    NOTE: Upon installation, apply clean engine oil to the O-ring seal.
  22. Remove the fuel level sensor O-ring seal.
  23. 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.
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