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Fuel Level Sensor: Installation

  1. Route the fuel gauge sending unit wire through the center of the fuel pump module.
  2. Fig 1: Routing Fuel Gauge Sending Unit Wire Through Center Of Fuel Pump Module
    G04005467Courtesy of FORD MOTOR CO.
    NOTE: Both fuel gauge sending unit wires must be routed behind the metal sending unit plate.
  3. Hook the fuel gauge sending unit on the fuel pump module.
  4. Fig 2: Hooking Fuel Gauge Sending Unit On Fuel Pump Module
    G04005468Courtesy of FORD MOTOR CO.
    NOTE: The grounding eyelet must be on the front side of the sending unit.
  5. Install the screw through the grounding eyelet and tighten the screw.
  6. Fig 3: Tightening Screw
    G04005469Courtesy of FORD MOTOR CO.
  7. Slide the heat shrink tube onto the wire harness and connect the electrical connector.
  8. Fig 4: Sliding Heat Shrink Tube Onto Wire Harness And Connecting Electrical Connector
    G04005470Courtesy of FORD MOTOR CO.
    WARNING: Do not use an open flame to heat the heat shrink tube, only use a heat gun.
  9. Using a heat gun, heat the heat shrink tube.
  10. Fig 5: Heating Heat Shrink Tube
    G04005471Courtesy of FORD MOTOR CO.
  11. Wrap the sending unit wire around the fuel pump module wire harness to make sure the wire will not interfere with the movement of the fuel gauge sending unit float arm.
  12. Fig 6: Wrapping Sending Unit Wire Around Fuel Pump Module Wire Harness
    G04005472Courtesy of FORD MOTOR CO.
  13. Install the fuel pump module. For additional information, Refer to FUEL PUMP .
  14. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .