Ford FOVY-9275-A Fuel Tank Sender Assembly

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To check and replace the fuel level sensor, first, raise and secure the vehicle on jackstands. For models with an analog gauge, disconnect the electrical connector for the fuel level sensor and turn on the ignition key to check the gauge operation. Use a test light to find the terminal with battery voltage and ground the terminal without voltage to test the gauge response. For models with a digital instrument cluster, perform a similar test using a voltmeter or test light and a 15-ohm resistor. Remove the resistor and use a 150-ohm resistor to check the gauge response. For a more accurate check, remove the sensor from the fuel tank and check its resistance manually operating the float arm. To replace the sensor, remove the fuel tank from the vehicle if necessary, and carefully remove the sensor, disconnect the electrical connector, and install the new unit using a new O-ring between the tank and the sensor cover.

Unbolt the fuel tank straps and lower the tank partially. Disconnect the fuel lines and electrical connector from the fuel pump assembly, and remove the assembly from the tank by tapping the locking ring counterclockwise. Replace the old lock ring gasket and clean or install the new strainer if necessary. Separate the fuel pump from the assembly by removing the clamp and disconnecting the electrical connector. Clean the mounting surfaces and seal ring groove before installing the new pump.

Use a new hose clamp on the fuel hose.

If there's no sound, check the fuel pump fuse, relay, and circuit. Also, check for battery voltage to the fuel pump relay connector and power relay connector. If there's no voltage, inspect the fuses and wiring circuit.

Attach the fuel pressure gauge to the test port and activate the fuel pump without starting the engine. Note the fuel pressure and start the engine to measure the pressure while idling.

If you notice excess fuel consumption or a fuel smell without any external leaks, examine the engine oil for signs of fuel mixing. Look for an abnormally high oil level and a thinned-out consistency with a fuel odor.