Ford 6W1Z-9A299-A
Fuel Gauge Sending Unit

Safety measures must be followed during fuel level sensor servicing because the system contains high-flammable mixtures. Mandatory safety precautions state that all parts connected to fuel should remain away from smoking or lit tobacco products along with open flames because such activity can create flame ignition of vapors thus causing severe harm to your body. The area where this work gets performed needs to stay free from personal electronic equipment including cell phones, pagers, and audio devices. Handling fuel with caution is always necessary since potential spills can generate ignitions from heated vehicle components or other ignition points. The first task is to disconnect the battery ground cable because it protects against ignition hazards. The initial step should be to remove the Fuel Pump (FP) module. Follow by removing the thermal insulation from the fuel level sensor electrical connector before disconnecting the cable. The disconnection of the fuel level sensor from the FP module requires removing the screws and unthreading the ground wire eyelet. The servicing operation ends with reversing the previous uninstallation procedures for installation of components.

The service of the fuel level sensor requires technicians to start with fuel tank removal. Disconnect the electrical connector for the pressure transducer which resides at the top rear side of the fuel tank and remove the two harness retainers from the tank. Handle the fuel pump with caution while cleaning around its mounting flange because any roughness may damage both the float arm and filter. Carefully remove the fuel pump by unfastening its six bolts and tighten the bolts to 10 Nm (89 lb-in) before installation. The old fuel pump mounting gasket deserves disposal before checking the contact areas between the fuel pump module flange and fuel tank seal. A new fuel pump module or fuel tank needs to be installed whenever the seal contact area shows bent or scratched or corroded condition. Recovery of the fuel pump installation requires performing procedures in the opposite order of removal.

Service on the fuel level sensor requires first removing power from the fire suppression system if one is present. You must remove the fuel tank first then disconnect the pressure transducer electrical connector which faces the top rear corner while also releasing its two harness retainers. Handle the fuel pump with care while cleaning the region surrounding its mounting flange and keep the float arm and filter free from damage. The six fuel pump retaining bolts need removal before installing the pump while tightening each bolt to 10 Nm (89 lb-in). The old fuel pump mounting gasket should be thrown away while checking the contact areas between the fuel pump module flange and fuel tank seal. These areas should receive no surface alteration or adjustment. Any bends, scratches or corrosion on the fuel pump module or fuel tank contact area requires replacement of the components. A new fuel pump module seal must be installed before following the reinstallation steps through the removal reversal procedure. As the last step, complete the reactivation of fire suppression devices if they were depowered.

Begin the service and repair of the fuel level sensor by guaranteeing safety through prevention of indoor smoking or using lighted tobacco or keeping any open flames away from fuel-related components because highly flammable mixtures can ignite causing serious personal injury. Cell phones along with audio devices should be left behind when working in this space. Totally adhere to all fuel handling procedures while also staying ready to manage possible fuel leakages due to hot vehicle elements. Always disconnect the battery ground cable before starting to work on the evaporative emission (EVAP) system or any fuel-related components. Before servicing any vehicle with fire suppression system operators must depower the system first. The service begins with removal of the fuel pump module followed by a removal of heat shrink tubing from the fuel level sensor connector before disconnecting it. To separate the fuel level sensor from the FP module it requires removing both screws and unmoving the ground wire eyelet. The procedure for installing the new sensor follows all actions done for removal in reverse order. The fire suppression system must be reactivated by following the protocol after the assembly process has been completed.

Remove the six bolts securing the fuel pump and install it by tightening to 10 Nm (89 lb-in).

Begin by removing the fuel tank.