Fuel Level Sending Unit/Sensor: Installation

WARNING: This page is about a different car, the 2004 Chrysler Pacifica. However, it is still accessible from the selected car via links, so may be relevant.

Install the fuel level sending card to module.

Fig 1: Installing The Fuel Level Sending Card
Courtesy of DAIMLERCHRYSLER CORP.
Connect the electrical connector for the fuel level sending card.

Fig 2: Connecting Electrical Connector
Courtesy of DAIMLERCHRYSLER CORP.
Install the fuel pump module top to the module (Fig 3) and (Fig 4).

Fig 3: Identifying Module Top Alignment Pins
Courtesy of DAIMLERCHRYSLER CORP.

Fig 4: Identifying Alignment Pins In Place
Courtesy of DAIMLERCHRYSLER CORP.
Install module into the tank with the level unit towards rear of tank.
Install a new seal onto the tank, making sure seal is properly seated in tank groove.
Install the Fuel Pump Module lock ring (Figure).
NOTE: Use a brass punch to Install the 1/4 turn lock ring. Make sure all 5 tabs are properly seated.
Connect the vapor line and electrical connector (Figure).
Install fuel tank. Refer to FUEL TANK .
Connect the negative battery cable.
Fill fuel tank. Use the DRBIII® scan tool to pressurize the fuel system. Check for leaks.