Fuel Level Sensor

Removal

NOTE: Removal steps in this procedure may contain installation details.

1. WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

   Refer to: Gasoline and Gasoline-Ethanol Fuel Systems Health and Safety Precautions (100-00 General Information, Description and Operation).
   

1. Remove the Fuel Tank.
   Refer to: Fuel Tank (310-01B Fuel Tank and Lines - 3.7L Duratec (227kW/301PS), Removal and Installation).
   

1. NOTICE: The Fuel Level Sensor must be handled carefully to avoid damage to the float arm.

   NOTE: Clean the Fuel Level Sensor connections, couplings, flange surfaces and the immediate surrounding are of any dirt or foreign material.

   NOTE: Some residual fuel may remain in the Fuel Level Sensor. Carefully drain into a suitable container.

   Carefully lift the Fuel Level Sensor from the fuel tank allowing access and disconnect internal transfer tube quick connect coupling. Remove the Fuel Level Sensor.
   Refer to: Quick Release Coupling (310-00B Fuel System - General Information - 3.7L Duratec (227kW/301PS), General Procedures).
   Special Tool(s) : 310-123 Locking Ring, Fuel Tank

1. NOTE: Inspect the surfaces of the Fuel Level Sensor flange and 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: Remove and discard the Fuel Level Sensor O-ring seal.

Installation

1. NOTE: Make sure to install a new Fuel Level Sensor O-ring seal.

   NOTE: Make sure the alignment tabs on the Fuel Level Sensor and the fuel tank meet prior to tightening the Fuel Level Sensor lock ring.

   To install, reverse the removal procedure.
   

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