Item 22: Fuel Gauge Sending Unit Installation Note

WARNING: This page is about a different car, the 2004 Mercury Monterey and 2004 Ford Freestar. However, it is still accessible from the selected car via links, so may be relevant.

Route the fuel gauge sending unit wire through the center of the fuel pump module.

Fig 1: Routing Fuel Gauge Sending Unit Wire Through Center Of Fuel Pump Module
Courtesy of FORD MOTOR CO.

NOTE: Both fuel gauge sending unit wires must be routed behind the metal sending unit plate. Hook the fuel gauge sending unit on the fuel pump module.

Fig 2: Identifying Fuel Pump Module

Courtesy of FORD MOTOR CO.

NOTE: The grounding eyelet must be on the front side of the sending unit.

Fig 3: Tightening Screw

Courtesy of FORD MOTOR CO.

Install the screw through the grounding eyelet and tighten the screw.
Slide the heat shrink tube onto the wire harness and connect the electrical connector.

Fig 4: Connecting Electrical Connector
Courtesy of FORD MOTOR CO.

WARNING: Do not use an open flame to heat the heat shrink tube, only use a heat gun.

Fig 5: Using Heat Gun To Heat Shrink Tube

Courtesy of FORD MOTOR CO.

Using a heat gun, heat the heat shrink tube.
Wrap the sending unit wire around the fuel pump module wire harness to make sure the wire will not interfere with the movement of the fuel gauge sending unit float arm.

Fig 6: Wrapping Sending Unit Wire Around Fuel Pump Module Wire Harness
Courtesy of FORD MOTOR CO.