Removal and Installation

WARNING: This page is about a different car, the 2011 Mercury Milan, 2011 Lincoln MKZ, and 2011 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

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.

NOTE: Only All-Wheel Drive (AWD) vehicles are equipped with a fuel level sensor (sub-side module) in the RH side of the saddle-type tank.

All vehicles

Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING & CABLES -- FUSION, MILAN & MKZ article.
Remove the rear seat lower cushion. For additional information, refer to SEAT SYSTEM - SEATS -- FUSION, MILAN & MKZ article.
3.0L vehicles with more than one-half of a tank of fuel

NOTE: The Easy Fuel™ (capless) fuel tank filler pipe on 3.0L vehicles have an anti-siphon grate that will not allow a fuel drain tube to penetrate the fuel tank and requires the following steps to drain the fuel.
With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING article.

NOTE: The supplemental refueling adapter is located in the luggage compartment.

Fig 1: Locating Supplemental Refueling Adapter And Semi-Rigid Fuel Drain Tube

Courtesy of FORD MOTOR CO.

Install the supplemental refueling adapter and a length of semi-rigid fuel drain tube into the Easy Fuel™ (capless) fuel tank filler pipe.
Attach the Fuel Storage Tanker to the fuel drain tube and remove any residual fuel in the fuel tank filler pipe.

NOTE: Index-mark the fuel tank filler pipe hose and the clamp prior to removal for correct installation.

Fig 2: Locating Fuel Tank Filler Pipe Hose Clamp

Courtesy of FORD MOTOR CO.

Release the clamp and disconnect the hose from the fuel tank filler pipe.
- To install, tighten to 4 Nm (35 lb-in).
Insert a semi-rigid fuel drain tube into the fuel tank filler pipe hose until it enters the fuel tank.

Fig 3: Locating Semi-Rigid Fuel Drain Tube
Courtesy of FORD MOTOR CO.

NOTE: This step is to remove approximately one-half tank of the fuel from a completely full fuel tank, lowering the fuel level below the fuel level sensor mounting flange.

Attach the Fuel Storage Tanker to the fuel drain tube and remove one-half (approximately 8 gallons) of fuel from the tank.
3.5L vehicles with more than one-half of a tank of fuel

NOTE: The supplemental refueling adapter is located in the luggage compartment.

Fig 4: Locating Supplemental Refueling Adapter And Semi-Rigid Fuel Drain Tube

Courtesy of FORD MOTOR CO.

Install the supplemental refueling adapter and a length of semi-rigid fuel drain tube into the Easy Fuel™ (capless) fuel tank filler pipe until the tube enters the fuel tank.

NOTE: This step is to remove approximately one-half tank of the fuel from a completely full fuel tank, lowering the fuel level below the fuel level sensor mounting flange.

Attach the Fuel Storage Tanker to the fuel drain tube and remove one-half (approximately 8 gallons) of fuel from the tank.
All vehicles
Remove the 3 screws and the fuel level sensor access cover.
- To install, tighten to 2 Nm (18 lb-in).

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

Disconnect the fuel level sensor electrical connector.

NOTE: Place absorbent pads in the general work area in case of fuel spillage.

Fig 5: Rotating Fuel Level Sensor Counterclockwise

Courtesy of FORD MOTOR CO.

Release the lock tab, rotate the fuel level sensor counterclockwise approximately one-fourth turn and lift upward.

NOTE: Inspect the mating surfaces of the fuel level sensor flange and the 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 fuel level sensor or fuel tank if the O-ring seal contact area is bent, scratched or corroded.

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

NOTE: Carefully remove the fuel level sensor from the fuel tank to avoid fuel spillage inside the vehicle.

Carefully lift and remove the fuel level sensor from the fuel tank.
To install, reverse the removal procedure.

Make sure the fuel level sensor locking tab is correctly positioned.