Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2005 Freightliner Sprinter 2500 L5-2.7L DSL TurboFACTORY OEM SERVICE PROCEDURE
Fuel Level Sensor: Service and Repair
REMOVAL
The fuel level sending unit (fuel level sensor) and float assembly is located on the side of the fuel pump module (4).
1. Remove fuel pump module from fuel tank. Refer to Fuel Pump Module Removal/Installation.
2. Unplug sensor's 2-wire harness from pump module electrical connector.
3. Before disconnecting wiring from 2-wire harness electrical connector, note position of each wire in the connector. Record this position.
4. Disconnect wiring from 2-wire harness electrical connector using a terminal pick/removal tool. Refer to Special Tools Wiring for tool part numbers.
5. To remove sending unit from pump module, press on plastic locking tabs (1) while sliding sending unit (4) on its tracks.
INSTALLATION
1. Noting their previous positions, connect wires from 2-wire harness into its connector.
2. Plug 2-wire harness connector into pump module electrical connector.
3. Position sending unit (4) to tracks on fuel pump module. Slide and snap into place.
4. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation.
Fuel Level Sensor:
The fuel level sending unit (fuel level sensor) and float assembly is located on the side of the fuel pump module (4).
1. Remove fuel pump module from fuel tank. Refer to Fuel Pump Module Removal/Installation.
2. Unplug sensor's 2-wire harness from pump module electrical connector.
3. Before disconnecting wiring from 2-wire harness electrical connector, note position of each wire in the connector. Record this position.
4. Disconnect wiring from 2-wire harness electrical connector using a terminal pick/removal tool. Refer to Special Tools Wiring for tool part numbers.
5. To remove sending unit from pump module, press on plastic locking tabs (1) while sliding sending unit (4) on its tracks.
INSTALLATION
Fuel Level Sensor:
1. Noting their previous positions, connect wires from 2-wire harness into its connector.
2. Plug 2-wire harness connector into pump module electrical connector.
3. Position sending unit (4) to tracks on fuel pump module. Slide and snap into place.
4. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation.
Factory Service Tools
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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.