Ford 9L3Z-9A299-F Fuel Tank Sender Assembly

Relieve the system fuel pressure and disconnect the cable from the negative battery terminal. Remove the fuel tank, ensuring to clean the tank surface thoroughly around the fuel pump module before removal to prevent dirt or debris from entering. Disconnect the fuel and EVAP line quick-connect couplings from the fuel pump/fuel level sensor. Using a hammer and a brass punch, loosen the lock ring that secures the fuel pump/fuel level sensor, then fully unscrew it. Lift the fuel pump/fuel level sensor assembly enough to access the quick-connect coupling for the EVAP line on the underside, disconnect it, and carefully lift the assembly out of the fuel tank, angling it as necessary to protect the float arm and float from damage. Remove and discard the old O-ring type seal. If reinstalling the original fuel pump unit, inspect the fuel inlet strainer; if slightly dirty, scrub it gently and rinse with clean solvent, but if too dirty to clean, replace the pump, as the strainer is a permanent part of the pump. Clean the fuel pump mounting flange and the tank mounting surface, especially where the O-ring type seal is installed. Use a new O-ring type seal and apply a thin coat of heavy grease to hold it in place during installation. After installing the fuel pump/fuel level sensor assembly in the fuel tank, ensure the alignment arrows on the pump mounting flange and the top of the fuel tank are aligned. Installation is otherwise the reverse of removal.

Remove the fuel tank and then take out the fuel pump and fuel level sensor from the tank, placing them on a clean workbench. Observe how the electrical wire for the fuel level sensor is bundled with the wiring for the fuel pump, ensuring the entire harness is routed correctly for proper function upon reassembly. Remove the heat shrink tubing from the electrical connector and disconnect the sensor's electrical connector. Note the location of the cable tie securing the harness for both components, cut it carefully with diagonal cutters without damaging any wires, and then remove the fuel level sensor mounting bolt to detach the sensor from the fuel pump assembly. Further disassembly of the fuel pump assembly is not possible, allowing for the installation of either the old fuel level sensor on a new fuel pump assembly or a new fuel level sensor on the old fuel pump assembly. Ensure the wiring harness is routed exactly as it was before disassembly and secure it with a new cable tie in the same location, with installation being the reverse of removal.