Removal and Installation

WARNING: This page is about a different car, the 2010 Lincoln MKX and 2010 Ford Edge. 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: 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.

WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Remove the fuel tank. For additional information, refer to FUEL TANK .

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

Disconnect the fuel level sensor electrical connector.
Release the lock tab, rotate the fuel level sensor counterclockwise approximately one-fourth turn, lift and remove the fuel level sensor.

Fig 1: Rotating Fuel Level Sensor
Courtesy of FORD MOTOR CO.

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: To install, apply clean engine oil to the O-ring seal.

NOTE: When installing, correctly seat and press down firmly on the fuel level sensor, rotate it clockwise until the lock arrow on the sensor aligns with the notch on the tank. Torque should not exceed 15 Nm (133 lb-in).

To install, reverse the removal procedure.