Crossfire, 2004-2005

Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.
  4.  
  5. Drain the fuel tank.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Place a shop towel around the fuel level sending unit/sensor to catch any excess fuel during disassembly.



    Cargo area interior trim panels
     
    Fuel tank partition retaining bolts and remove the fuel tank partition
     
    Fuel level sending unit/sensor harness connector (1)
     




  8.  
  9. Install Special Tool 9240 (5) or a suitable fuel line safety barb disconnector and rotate the fuel level sending unit/sensor (2) counterclockwise.
  10.  
  11. Remove the fuel level sending unit/sensor (2) from the fuel tank (4).

    Click image to see an enlarged view

    Fig. Exploded view of fuel level sending unit/sensor-all models

  12.  

To install:

  1. Install fuel level sending unit/sensor into the fuel tank.
  2.  
  3. Install Special Tool 9240 and rotate the fuel level sending unit/sensor clockwise fully to stop.
  4.  
  5. Connect the fuel level sending unit/sensor harness connector.
  6.  
  7. Install the fuel tank partition into the cargo area, install the retaining bolts and tighten to 7 ft. lbs. (10 Nm).
  8.  
  9. Install the cargo area interior trim panels.
  10.  
  11. Refill the fuel tank to the prior level.
  12.  
  13. Connect the negative battery cable.
  14.  

 
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