1. Disconnect Negative Battery Cable
Disconnect the negative battery cable to avoid any electrical accidents during the process.
2. Remove Fuel from Tank
Reduce the fuel level in the fuel tank to around one-quarter to lower the risk of spills and make it easier to handle the gas tank.
3. Locate the Fuel Sending Unit
The fuel sending unit is usually located on top of the fuel tank. It consists of a sensor that monitors fuel level and a fuel pump.
4. Disconnect Fuel Line
Disconnect the fuel line and return hose from the fuel sending unit. Make sure to release any pressure in the fuel line before doing so.
5. Remove Electrical Connectors
Unplug any electrical connectors attached to the fuel sending unit. Remember the location of each connector for proper reinstallation.
6. Remove Fuel Tank Lock Ring
On top of the fuel tank, you'll find a lock ring holding the fuel sending unit in place. Use a wrench or socket to loosen and remove the lock ring.
7. Remove Fuel Sending Unit
After taking off the lock ring, you can pull the fuel sending unit out of the fuel tank. Be careful as there may still be some fuel left inside the sending unit.
8. Replace Fuel Filter and Pump (If Needed)
If the fuel filter or fuel pump is incorporated into the fuel sending unit and requires replacement, do it at this stage.
9. Reinstall Fuel Sending Unit
Carefully lower the new or repaired fuel sending unit into the tank. Ensure that the unit is properly seated, and the gasket forms a tight seal.
10. Reinstall Lock Ring
Replace and secure the lock ring that holds the fuel sending unit in place. Tighten it securely to prevent leakage.
11. Reconnect Electrical Connectors
Reconnect all electrical connectors you disconnected earlier to the fuel sending unit.
12. Reconnect Fuel Line
Reconnect the fuel line and return hose to the fuel sending unit, ensuring they click into place and form tight connections.
13. Restore Fuel Level
Add fuel to the tank until it reaches the desired level.
14. Reconnect Battery Cable
Reconnect the negative battery cable you disconnected at the beginning of the process.
15. Test Fuel Sending Unit
Turn on the ignition to check if the fuel gauge is working correctly and provides accurate fuel level readings.
By following these steps, you should be able to successfully replace the fuel sending unit on your 1997 Mercury Tracer Trio Sport. Remember to take necessary safety precautions and consider seeking help from a professional mechanic if you are unsure about any step or encounter difficulties during the process.
