Fuel Level Sending Unit / Sensor: Removal

WARNING: This page is about a different car, the 2004 Dodge Intrepid, 2004 Chrysler Intrepid, 2004 Chrysler Concorde, and 2004 Chrysler 300M. However, it is still accessible from the selected car via links, so may be relevant.

Remove fuel pump module. Refer to FUEL PUMP MODULE .

Depress the retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector (Fig 1).

Fig 1: Fuel Pump/Level Sensor Connector
Courtesy of DAIMLERCHRYSLER CORP.
Remove wire terminal retaining clip from connector (Fig 2). Note the location of terminals for the level sensor wires (Fig 3).

Fig 2: Wire Terminal Retaining Clip
Courtesy of DAIMLERCHRYSLER CORP.

Fig 3: Wire Terminal Identification
Courtesy of DAIMLERCHRYSLER CORP.
Using special tool 7812 or an equivalent, push level sensor signal and ground terminals out of the connector (Fig 4).

Fig 4: Level Sensor Signal
Courtesy of DAIMLERCHRYSLER CORP.
Insert a screwdriver between the fuel pump module and the top of the level sensor housing (Fig 5). Push level sensor down slightly.

Fig 5: Fuel Level Sensor Removal
Courtesy of DAIMLERCHRYSLER CORP.
Slide level sensor wires through standpipe inside fuel pump module (Fig 6).

Fig 6: Standpipe Inside Of Module
Courtesy of DAIMLERCHRYSLER CORP.
Slide level sensor out of installation channel (Fig 5).