Fuel Level Sensor: Installation

CAUTION: Inspect the surfaces of the fuel level sensor mounting flange and the fuel tank O-ring seal contact surfaces. Do not polish or adjust the O-ring 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.

CAUTION: Make sure to install a new fuel level sensor O-ring seal and lock ring.

NOTE: Prior to installing the fuel level sensor and O-ring seal, thoroughly clean any contaminants from fuel level sensor and fuel tank mounting flanges.

NOTE: Upon installation, apply clean engine oil to the O-ring seal.

Install the new fuel level sensor O-ring seal.
Position the fuel level sensor into the fuel tank.
Connect the crossover fuel tube-to fuel level sensor quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .

Fig 1: Locating Fuel Level Sensor

Courtesy of FORD MOTOR CO.

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

Using the special tool, install the new fuel level sensor retaining lock ring.
- Tighten the lock ring until it meets the stops on the fuel tank.

Fig 2: Installing New Fuel Level Sensor Retaining Lock Ring Using Special Tool 310-D006

Courtesy of FORD MOTOR CO.

Connect the fuel level sensor electrical connector.

Fig 3: Locating Fuel Level Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

CAUTION: Make sure to install a new FP module O-ring seal and lock ring.

CAUTION: Inspect the surfaces of the FP module mounting flange and the fuel tank O-ring seal contact surfaces. Do not polish or adjust the O-ring contact area of the fuel tank flange or the fuel tank. Install a new FP module or fuel tank if the O-ring seal contact area is bent, scratched or corroded.

NOTE: Prior to installing the FP module and O-ring seal, thoroughly clean any contaminants from FP module and fuel tank mounting flanges.

NOTE: Upon installation, apply clean engine oil to the O-ring seal.

Install the new FP module O-ring seal.
Position the FP module into the fuel tank.
Connect the crossover fuel tube-to- the FP module quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .

Fig 4: Locating Cross-Over Fuel Tube Quick Connect Coupling

Courtesy of FORD MOTOR CO.

NOTE: Make sure the alignment arrows on the FP module and the fuel tank meet before tightening the FP module lock ring.

Using the special tool, install the new FP module retaining lock ring.
- Tighten the lock ring until it meets the stops on the fuel tank.
Connect the rear fuel supply tube-to-FP module quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .

Fig 5: Locating Quick Connect Coupling On FP Module

Courtesy of FORD MOTOR CO.

Connect the FP module electrical connector.

Fig 6: Locating FP Module Electrical Connector

Courtesy of FORD MOTOR CO.

NOTE: Remove and discard the absorbent pads.

Install the FP module and the fuel level sensor access covers.

Fig 7: Locating FP Module Access Cover

Courtesy of FORD MOTOR CO.

Install any insulation padding covering the FP module and fuel level sensor access covers.
Install the rear seat cushion. For additional information, refer to SEATING .
Using the fuel storage tanker, refuel the fuel tank.
Install the fuel tank filler cap.

Fig 8: Locating Fuel Tank Filler Cap

Courtesy of FORD MOTOR CO.

Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .

NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system.

Check for leaks before starting the engine.
Start the engine and check for leaks.