Removal And Installation

WARNING: This page is about a different car, the 2008 Ford Pickup, 2008 Ford F550 Super Duty, 2008 Ford F450 Super Duty, and 2008 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: This procedure is for diesel applications only.

NOTE: The fuel tank must be drained completely. Upon removal of the fuel level sensor, the tank must be inspected for contamination.

Remove the fuel tank. For additional information, refer to Fuel Tank - Aft-of-Axle or Fuel Tank - Auxiliary .

CAUTION: Clean the fuel tank of any dirt or foreign material before servicing the fuel level sensor. In extreme dirt or dusty conditions it may be necessary to wash the fuel tank using a water hose. Before removing the fuel level sensor, make sure that there is no residual dirt or foreign material around the fuel level sensor flange. If dirt or foreign material enter the fuel tank, damage to the fuel level sensor or other fuel system components may occur.

Clean the area around the fuel level sensor mounting flange.
Remove the 6 bolts from the fuel level sensor.
- To install, tighten to 10 Nm (89 lb-in).

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

Completely remove the fuel level sensor from the fuel tank.

NOTE: Inspect the surfaces of the fuel level sensor flange and fuel tank gasket contact surfaces. Do not polish or adjust the gasket contact area of the fuel tank flange or the fuel tank. Install a new fuel level sensor or fuel tank if the gasket contact area is bent, scratched or corroded or fuel leakage could occur causing vehicle damage.

NOTE: Make sure to install a new fuel level sensor gasket or fuel leakage could occur causing vehicle damage.

Remove and discard the fuel level sensor gasket.
To install, reverse the removal procedure.