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Fuel Level Sending Unit/Sensor: Removal

  1. Release the fuel pressure. Refer to FUEL SYSTEM PRESSURE RELEASE PROCEDURE  .
  2. Disconnect the negative battery cable.
  3. Remove fuel tank. Refer to FUEL TANK .
  4. Vacuum area before removing fuel pump module lock ring.
  5. Disconnect the vapor line and electrical connector (Fig 1).
    Fig 1: Identifying Electrical & Vapor Connector
    G03572726Courtesy of DAIMLERCHRYSLER CORP.
  6. Fuel Pump Module Lock ring contact points (Fig 2) and (Fig 3).
    Fig 2: Identifying Pump Module Locking Ring
    G03572727Courtesy of DAIMLERCHRYSLER CORP.
    Fig 3: Identifying Locking Ring Contact Points
    G03572728Courtesy of DAIMLERCHRYSLER CORP.
  7. Remove the Fuel Pump Module lock ring (Fig 4).
    NOTE: Use a brass punch to remove the 1/4 turn lock ring.
    Fig 4: Removing Module Lock Ring
    G03572729Courtesy of DAIMLERCHRYSLER CORP.
  8. Remove the fuel pump module top.
  9. Tip Fuel Pump Module on to it's side to drain fuel from the reservoir in the module.
  10. Drain Fuel Tank, use an approved GASOLINE draining station.
  11. Disconnect the electrical connector for the fuel level sending card.
  12. Remove the fuel level sending card by prying on the locking tab (Figure) and pulling the card down toward the bottom of the pump module. There are 2 locking tabs on the sending card, one on the front and one on the back (Figure).