Ford 5C3Z-9275-BA
Fuel Gauge Sending Unit

Special safety protocols must be followed when servicing the fuel gauge sender and fuel pump module inside a steel fuel tank because dangerous highly flammable mixtures exist. Avoid placing any open flames and smoking within close distance to fuel-related equipment. Any fuel system components require the user to release fuel system pressure before disconnection to stop dangerous fuel spray that can cause fires. The specified procedure works exclusively for gasoline systems. The first step involves removing all the fuel from the tank to let the technician thoroughly examine for any contaminations before removing the fuel pump module. Before installing or removing the fuel pump module you must clean its mounting flange area while tightening its six mounting bolts to 10 Nm (89 lb-in). When manipulating the fuel pump module ensure both the float arm remains undamaged and the module exits the fuel tank fully. Deliberately alter the surfaces where the fuel pump module meets the fuel tank only when surfaces are damaged because replacing the module or tank may become necessary. Install new part number 10085169 fuel pump module gasket and dispose of the old one when replacing and follow the reverse steps of removal to finish the installation.

Caring service of the fuel gauge sender and fuel pump module inside steel fuel tanks needs strict precautions because these tanks contain highly volatile mixtures. The area surrounding fuel components must remain free from both fire and smoking activities. A fire hazard develops from accidental fuel spraying when you remove fuel system components so you must first release fuel system pressure. First empty the fuel tank completely then check for contaminants when the fuel pump module is taken out. Clean the fuel pump flange installation area followed by removal of the six securing bolts which need to be tightened to 10 Nm (89 lb-in) during reinstallation. Exercise gentle handling of the fuel pump module while carefully protecting the float arm and pull it completely out from the fuel tank. The inspector should examine fuel pump module flange surfaces alongside fuel tank gasket contact areas yet should avoid adjusting or polishing surface regions if they present bending, scrapping or corrosion because this will lead to new fuel pump module or fuel tank requirements. The process requires using a new fuel pump module gasket which needs to be discarded and then following the removal procedure backwards.

Clean the area around the fuel level sensor mounting flange.

Clean the area around the sensor's mounting flange and then remove the six bolts securing the fuel level sensor.