Fuel Level Sensor (Diesel): Installation

WARNING: This page is about a different car, the 2011 Ford Pickup, 2011 Ford F550 Super Duty, 2011 Ford F450 Super Duty, and 2011 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Inspect the mating surfaces of the fuel level sensor flange and the fuel tank O-ring seal contact surfaces. Wipe clean with a lint-free rag.

NOTE: Manually sweep the float arm to ensure freedom of travel.

Install a new fuel level sensor O-ring seal.

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

Install the fuel level sensor by inserting float rod through fuel tank opening first.

NOTE: Carefully install the lock ring wrench to avoid damaging the fuel level sensor when installing the lock ring.

NOTE: Install a new lock ring if it is bent, damaged or corroded.

NOTE: Make sure the alignment tab on the fuel level sensor and the fuel tank meet before tightening the fuel tank lock ring.

Fig 1: Identifying Fuel Tank Sender Unit Wrench

Courtesy of FORD MOTOR CO.

Install the lock ring wrench and tighten the fuel level sensor lock ring.
Install the fuel tank. For additional information, refer to REMOVAL AND INSTALLATION .