Mercury 6W1Z-9A299-A Fuel Tank Sender Assembly

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Raise the vehicle and support it securely on jackstands. Disconnect the electrical connector for the fuel level sensor. Note: On 1998 and earlier models, disconnect the electrical connector at the pump. On 1999 and later models, the electrical connector is located in the harness and must be disconnected at the electrical connector away from the tank. Position the ohmmeter probes into the electrical connector and check the resistance. Use the 200-ohm scale on the ohmmeter. With the fuel tank completely full, the resistance should be about 170.0 ohms. With the fuel tank nearly empty, the resistance of the sensor should be about 11.0 ohms. If the readings are incorrect, replace the sensor. A more accurate check of the sensor can be made by removing it from the fuel tank and checking its resistance while manually operating the float arm. Remove the fuel pump/sensor assembly from the vehicle. Carefully angle the sensor out of the opening without damaging the fuel level float located at the bottom of the assembly. Remove the sensor electrical connector from the fuel pump assembly. Remove the screws that secure the sensor to the fuel pump assembly. Installation is the reverse of removal. If the float arm and float wire loop were damaged or bent during removal and installation, adjust the angle and travel distance. Be sure to install a new rubber gasket.

Raise the vehicle and support it securely on jackstands. Disconnect the electrical connector for the fuel level sensor. Note: On 1998 and earlier models, disconnect the electrical connector at the pump. On 1999 and later models, the electrical connector is located in the harness and must be disconnected at the electrical connector away from the tank. Position the ohmmeter probes into the electrical connector and check the resistance. Use the 200-ohm scale on the ohmmeter. With the fuel tank completely full, the resistance should be about 170.0 ohms. With the fuel tank nearly empty, the resistance of the sensor should be about 11.0 ohms. If the readings are incorrect, replace the sensor. A more accurate check of the sensor can be made by removing it from the fuel tank and checking its resistance while manually operating the float arm. Remove the fuel pump/sensor assembly from the vehicle. Carefully angle the sensor out of the opening without damaging the fuel level float located at the bottom of the assembly. Remove the sensor electrical connector from the fuel pump assembly. Remove the screws that secure the sensor to the fuel pump assembly. Installation is the reverse of removal. If the float arm and float wire loop were damaged or bent during removal and installation, adjust the angle and travel distance. Be sure to install a new rubber gasket.