Fuel Level Sensor

Replace the fuel level sensor in the fuel tank, requiring tank removal to access the fuel pump module assembly containing the sensor.

Warnings

Tools required

Parts

• Fuel level sensor × 1 — Use OEM specification
• Fuel pump module O-ring × 1 — Use OEM specification
• Fuel line O-rings × 4 — Use OEM specification

Preparation

1. Park vehicle on level ground in a well-ventilated area away from all ignition sources
2. Ensure fuel level is below half tank if possible to reduce draining time
3. Disconnect negative battery cable and isolate terminal to prevent sparks
4. Allow exhaust system to cool completely if vehicle was recently driven
5. Chock front wheels securely
6. Raise rear of vehicle and support securely on jack stands at manufacturer-specified lift points
7. Place fire extinguisher within easy reach

Procedure

1. 1

   Relieve fuel system pressure
   Remove fuel filler cap to relieve tank pressure. Locate the fuel pump relay (verify location against Viper service documentation). Remove the fuel pump relay and attempt to start the engine. The engine will run briefly then stall as fuel pressure is depleted. Crank the engine for an additional 5 seconds to ensure all pressure is relieved. Turn ignition off.
   ⚠️Residual pressure may remain in fuel lines even after this procedure. Keep rags ready when disconnecting fuel lines.
2. 2

   Drain fuel tank
   Using an approved fuel siphon pump, drain fuel from tank through the fuel filler neck. Transfer fuel to approved storage containers. Drain as much fuel as possible to minimize weight and spillage during tank removal. The tank holds approximately 22 gallons when full (verify capacity against Viper service documentation).
   ⚠️Use only approved fuel storage containers. Never drain gasoline into open buckets or unapproved containers.
3. 3

   Disconnect fuel filler neck
   Locate the fuel filler neck hose connection at the rear of the tank. Loosen the hose clamp securing the filler neck to the tank using a socket or screwdriver. Carefully work the filler neck hose off the tank inlet pipe. Also disconnect the vent hose from the tank using the same method. Note: Socket set (metric and SAE)
   ⚠Some fuel will drain from filler neck. Have drain pan positioned to catch spillage.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
4. 4

   Disconnect fuel lines
   Locate the fuel supply and return lines at the front of the fuel tank where they connect to hardlines. These are quick-disconnect fittings. Using the appropriate fuel line disconnect tool for the fitting size, compress the tabs and pull the fuel line straight off the fitting. Some residual fuel will spill; use shop towels to contain it. Cap or plug the open hardlines to prevent contamination.
   ⚠Fuel will spill when lines are disconnected. Have drain pan and rags positioned to catch spillage.
5. 5

   Disconnect electrical connections
   Locate the fuel pump module electrical connector on top of the fuel tank. Press the connector locking tab and carefully disconnect the electrical connector. Inspect connector and terminals for corrosion or damage.
   ℹ️The connector may be stiff from age. Do not force; ensure locking tab is fully released before pulling.
6. 6

   Support fuel tank
   Position a floor jack with a wide wooden board on top under the center of the fuel tank. Raise the jack until it just contacts the tank and provides light support. The tank should not be lifted, only supported. Note: Even a drained tank is heavy and awkward to handle; verify the empty tank weight and handling requirements against service documentation.
   ⚠Tank must be securely supported before removing straps. Even a drained tank weighs approximately 50 pounds and is awkward to handle.
7. 7

   Remove fuel tank straps
   Locate the fuel tank mounting straps that secure the tank to the chassis (verify strap count and bolt arrangement against Viper service documentation). Remove the strap mounting bolts completely using a socket and ratchet. Carefully pivot the straps down and away from the tank. The tank will now be resting on the jack only.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
8. 8

   Lower and remove fuel tank
   Carefully lower the jack, bringing the fuel tank down slowly. As you lower the tank, verify all hoses, lines, and electrical connections have been disconnected. Once clear of the vehicle, carefully slide the tank out from under the vehicle. Place the tank on a clean work surface with the top facing up.
   ⚠Tank may still contain residual fuel. Keep level during removal to prevent spillage.
9. 9

   Remove fuel pump module lock ring
   Clean the area around the fuel pump module on top of the tank to prevent debris from entering the tank. The fuel pump module is secured by a large locking ring with tabs. Using a brass punch and hammer (or appropriate lock ring tool), tap the tabs counterclockwise to unthread the lock ring. Remove the lock ring completely.
   ⚠Do not use steel punches that could create sparks. Use brass or plastic tools only.
10. 10

    Remove fuel pump module assembly
    Carefully lift the fuel pump module assembly straight up and out of the tank opening. The fuel level sensor is attached to the side of the pump module assembly. Tilt the assembly as needed to clear the tank opening while being careful not to damage the fuel level sensor float arm. Note the orientation of the module for reinstallation. Remove and discard the large O-ring seal from the tank opening.
    ⚠Residual fuel will drain from the module. Have a drain pan ready and allow fuel to drain back into tank before fully removing module.
11. 11

    Replace fuel level sensor
    Place the fuel pump module on a clean work surface. Locate the fuel level sensor attached to the side of the module housing. Disconnect the electrical connector from the sensor. Remove the fastener(s) securing the fuel level sensor to the module. Carefully remove the old sensor, taking care not to damage the float arm. Install the new fuel level sensor in the same orientation, ensuring the float arm moves freely through its full range of motion. Secure with the fastener(s) and reconnect the electrical connector.
    ℹ️Verify the float arm moves freely and does not bind against any part of the module assembly.
12. 12

    Reinstall fuel pump module assembly
    Clean the fuel tank mounting flange thoroughly using a wire brush and shop towels. Install a new O-ring seal in the groove on the tank opening. Lubricate the O-ring lightly with clean engine oil. Carefully lower the fuel pump module assembly into the tank, aligning it in the same orientation as removed. Ensure the O-ring remains properly seated. Press the module down fully into the tank opening.
    ℹ️Do not reuse the old O-ring. A leaking seal will cause fuel odor and potential fire hazard.
13. 13

    Install fuel pump module lock ring
    Position the lock ring over the fuel pump module. Thread the lock ring clockwise by hand until it seats. Using a brass punch and hammer (or appropriate lock ring tool), tap the tabs clockwise to tighten the lock ring securely. The lock ring should be tight enough that it cannot be loosened by hand.
    ⚠Do not overtighten lock ring. Excessive force can damage the tank threads or module flange.
14. 14

    Reinstall fuel tank
    Position the fuel tank on the jack with wooden support board. Carefully raise the tank into position under the vehicle, routing the filler neck and vent hose as you lift. Ensure no wires or hoses are pinched. When the tank is in its mounting position, swing the fuel tank straps up and over the tank. Install the strap mounting bolts and tighten to the Viper-specific torque specification (verify value in service documentation).
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
15. 15

    Reconnect all connections
    Reconnect the fuel pump module electrical connector, ensuring it locks securely. Install new O-rings on the fuel line quick-connect fittings. Push the fuel supply and return lines onto their respective fittings until they click into place. Tug on each line to verify secure connection. Reconnect the fuel filler neck hose to the tank inlet pipe and secure with the hose clamp. Reconnect the vent hose and secure with its clamp.
    ⚠Always install new O-rings on fuel line connections. Reusing old O-rings can result in fuel leaks.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)
16. 16

    Refill fuel tank and test system
    Lower the vehicle. Reconnect the negative battery cable. Reinstall the fuel pump relay in the power distribution center. Add a minimum of 5 gallons of fresh gasoline to the fuel tank. Turn the ignition to ON position (do not start engine) and listen for the fuel pump to run for approximately 2 seconds. Cycle the ignition OFF then ON again 3-4 times to prime the fuel system. Inspect all fuel line connections and the tank for any signs of leakage. Start the engine and allow it to idle. Recheck all connections for leaks.
    ⚠️If any fuel leaks are detected, immediately turn off engine and correct the leak before proceeding.

Reassembly

1. Torque all fasteners to specification as outlined in the steps above
2. Always use new O-rings on all fuel system connections
3. Ensure fuel tank straps are properly seated before tightening mounting bolts
4. Verify all electrical connections are fully seated and locked

Verification

• With engine running, inspect entire fuel system for leaks, including tank seam, filler neck, fuel lines, and pump module seal
• Check for fuel odors in cabin or near fuel tank area
• Verify fuel gauge reads correctly with known fuel quantity in tank
• Test fuel gauge through full range by adding fuel and observing gauge movement from empty toward full
• Drive vehicle and verify fuel gauge reading decreases appropriately with fuel consumption
• Recheck all connections for leaks after test drive

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