2005 Chrysler 300 BaseFACTORY OEM SERVICE PROCEDURE

Right Side Module

Fig 1: LEVEL CARD LOCKING TABS
GC0013043Courtesy of DAIMLERCHRYSLER CORP.
  1. Install level sending card, make sure that the locking tabs are locked on the card.
    Fig 2: LEVEL CARD WIRES PASS SIDE
    GC0013042Courtesy of DAIMLERCHRYSLER CORP.
  2. Route wires in the proper location.
  3. Tie strap the wires harness to the hoses.
    Fig 3: MODULE PASS SIDE
    GC0013050Courtesy of DAIMLERCHRYSLER CORP.
  4. Feed hoses and wiring harness into fuel tank and over the center hump in tank.
    Fig 4: RIGHT SIDE MODULE ORIENTATION
    GC0013045Courtesy of DAIMLERCHRYSLER CORP.
  5. Install module and align marks on the module for proper orientation.
    Fig 5: TOOL 9430 RIGHT SIDE MODULE
    GC0013047Courtesy of DAIMLERCHRYSLER CORP.
  6. Install module lock-ring.
  7. Use special tool #9340 to tighten right side module lock ring.
  8. Connect the fuel supply line to module.
    Fig 6: ACCESS COVER RIGHT SIDE MODULE
    GC0013044Courtesy of DAIMLERCHRYSLER CORP.
  9. Install plastic access covers to floor pan right side.
    Fig 7: HOSE CONNECTIONS DR SIDE
    GC0013056Courtesy of DAIMLERCHRYSLER CORP.
  10. Install the fuel return hoses to module.
  11. Install fuel supply line to module.
    Fig 8: PUMP MODULE DR SIDE
    GC0013054Courtesy of DAIMLERCHRYSLER CORP.
  12. Make sure that wires are routed properly.
    Fig 9: WIRE TIE STRAP
    GC0013058Courtesy of DAIMLERCHRYSLER CORP.
  13. Make sure that the level sending card wire is tie strapped to the fuel supply line at the module.
    Fig 10: ELECTRICAL CONNECTORS
    GC0013040Courtesy of DAIMLERCHRYSLER CORP.
  14. Install left side module top to module bottom.
    Fig 11: ELECTRICAL CONNECTOR LEFT SIDE CARD
    GC0013039Courtesy of DAIMLERCHRYSLER CORP.
  15. Connect the electrical connectors for right side fuel level sending card, left side module card. Make sure that wires are routed properly.
    Fig 12: LEFT SIDE MODULE ORIENTATION
    GC0013034Courtesy of DAIMLERCHRYSLER CORP.
  16. Install module and align marks on the module for proper orientation.
    Fig 13: TOOL 9430 LEFT SIDE MODULE
    GC0013036Courtesy of DAIMLERCHRYSLER CORP.
  17. Install module lock-ring.
  18. Use special tool #9340 to tighten left side module lock ring.
  19. Connect the electrical connector to left side module and install plastic access cover.
    Fig 14: FOAM PAD UNDER SEAT
    GC0013033Courtesy of DAIMLERCHRYSLER CORP.
  20. Fold the foam pad covering access cover for modules back into place.
    Fig 15: REAR SEAT UP
    GC0013029Courtesy of DAIMLERCHRYSLER CORP.
  21. Install rear lower seat cushion
    Fig 16: REAR SEAT
    GC0013028Courtesy of DAIMLERCHRYSLER CORP.
  22. Rear lower seat cushion installed.
    Fig 17: DRAINING FUEL
    GC0013027Courtesy of DAIMLERCHRYSLER CORP.
  23. Fill fuel tank.
  24. Connect negative battery cable.
  25. Fill fuel tank. Use the scan tool to pressurize the fuel system. Check for leaks.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.