| Removal and Installation Removal All except vehicles with diesel engine | | -
Remove the fuel pump and sender unit.
For additional information, refer to: Fuel Tank - 1.6L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT (Sigma)/1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (310-01 Fuel Tank and Lines, Removal and Installation).
| Vehicles with diesel engine | | -
Remove the fuel level sensor.
For additional information, refer to: Fuel Tank - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Vehicles With: Fuel Additive Tank (310-01, Removal and Installation) /
Fuel Tank - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Vehicles Without: Fuel Additive Tank (310-01, Removal and Installation).
| All vehicles | | -
NOTE:Make a note of the position and colors of the wiring before disconnecting the electrical connectors to aid installation. NOTE:Diesel engine variants only have 2 wires. Disconnect the fuel level resistor card electrical connectors. | | | -
Remove the fuel level resistor card. - Release the locking tang at the rear of the fuel level resistor card.
- Discard the fuel level resistor card.
| Installation All vehicles | | -
CAUTION:Do not touch the fuel level resistor card surface with tools or hands. Failure to follow this instruction may result in damage to the fuel level resistor card. NOTE:An audible click will be heard when the fuel level resistor card is correctly installed. Install the new fuel level resistor card. | | | -
NOTE:Diesel engine variants only have 2 wires. Connect the fuel level resistor card electrical connectors to the noted positions. | | | -
Make sure that the float rod and arm are able to sweep their full ranges without contacting or fouling on any wires. | Vehicles with diesel engine | | -
NOTE:Install a new fuel level sensor gasket. Install the fuel level sensor.
For additional information, refer to: Fuel Tank - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Vehicles With: Fuel Additive Tank (310-01, Removal and Installation) /
Fuel Tank - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Vehicles Without: Fuel Additive Tank (310-01, Removal and Installation).
| All except vehicles with diesel engine | | -
NOTE:Install a new fuel pump and sender unit gasket. Install the fuel pump and sender unit.
For additional information, refer to: Fuel Tank - 1.6L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT (Sigma)/1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (310-01 Fuel Tank and Lines, Removal and Installation).
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