Replacing Fuel Level Sender In A 2007 Dodge Charger

The fuel level sending unit in your car is an important component that helps you monitor your fuel levels. Located in the fuel tank, it consists of a float connected to a metal rod and a resistor, which measures electrical flow. When your fuel gauge isn't working, it could be due to a faulty fuel level sending unit. In this article, we will discuss the process of replacing the fuel level sending unit in a 2007 Dodge Charger, ensuring you stay on top of your car's maintenance and keeping you safely on the road.

Disconnect the battery and remove the fuel tank

Disconnecting the battery and removing the fuel tank are crucial steps in replacing the fuel level sender on a 2007 Dodge Charger. Here is a detailed guide on how to perform these steps safely and effectively:

Disconnect the Battery:

• Park your Dodge Charger on a flat, level surface and engage the parking brake.
• Open the hood of your vehicle and locate the battery.
• Identify the negative terminal of the battery, which is usually marked with a "-" sign.
• Disconnect the negative battery cable from the terminal. This step is essential to ensure that the power to the fuel pump and sending unit is disabled.

Remove the Fuel Tank:

• Place wheel chocks around the front tires to prevent the vehicle from moving.
• Jack up the rear of the vehicle at the specified jacking points and secure it with jack stands.
• Locate the fuel tank under the vehicle.
• Loosen and remove the straps or clamps holding the fuel tank in place.
• Disconnect any hoses or lines connected to the fuel tank, such as the vent hose and fuel filler neck.
• Carefully lower the fuel tank and remove it from the vehicle.

Note: It is recommended to have the fuel tank at a quarter full or less before proceeding with the fuel level sender replacement.

Now that the battery is disconnected and the fuel tank removed, you can proceed to replace the fuel level sender. Remember to exercise caution when working with fuel systems and refer to a trusted repair manual or seek professional assistance if needed.

Remove the old fuel level sender

To remove the old fuel level sender from your 2007 Dodge Charger, you'll need to follow a detailed process that involves working with the vehicle's fuel system. Here's a step-by-step guide on how to do it safely and effectively:

Park your vehicle and prepare for work:

• Park your Dodge Charger on a flat, hard surface and ensure the transmission is in park (for automatics) or in first gear (for manuals).
• Engage the parking brake to lock the rear tires from moving.
• If desired, you can install a nine-volt battery saver into the cigarette lighter to keep your computer live and maintain current settings.

Accessing the fuel tank and sender unit:

• Open the hood and disconnect the negative cable from the battery to disable power to the fuel pump and sending unit.
• Raise the vehicle using a jack, lifting it at the specified jacking points until the wheels are off the ground.
• Place jack stands under the vehicle for support.
• Remove the fuel filler cap cable from the fuel neck and open the fuel door to access the fuel filler neck.
• Remove any mounting screws or bolts attached to the cutaway.
• Locate the fuel tank and use a transmission jack or similar tool to lower it slightly.

Disconnecting the fuel pump and sender unit:

• Disconnect the harness from the connector by feeling for it attached to the tank. This is typically for the fuel pump or sending unit on older vehicles.
• Further lower the fuel tank to access and remove the vent hose attached to it. You may need to remove a clamp and small vent hose for more clearance.
• Remove the fuel filler neck by twisting it out of the rubber hose and guiding it out of the way.

Removing the fuel tank and old sender unit:

• Before removing the fuel tank, ensure you transfer any fuel out of it into a safe container.
• Clean the harness on the vehicle and the connector to the fuel pump or sending unit on the fuel tank using electrical cleaner and a lint-free cloth.
• Remove any dirt or debris around the fuel pump and sender mounting area.
• Remove the mounting bolts securing the fuel pump and sender to the fuel tank.
• Pull out the fuel pump and sender from the fuel tank, and remove the rubber seal. You may need to rotate the fuel sender to get the float out.

Now that you have removed the old fuel level sender, you can proceed to install a new one, ensuring you follow the manufacturer's instructions and safety guidelines. Working with fuel systems can be dangerous, so always exercise caution and refer to a professional mechanic if you're unsure about any steps.

Install the new fuel level sender

To install the new fuel level sender, follow these steps:

• Install a new rubber gasket onto the fuel tank, followed by the new fuel pump with the attached sender.
• Secure the fuel pump and sender using the mounting bolts. Tighten the bolts by hand, then give them an extra turn of approximately 1/8th.
• Refit the fuel tank in the vehicle.
• Reconnect the vent hose to the fuel tank, ensuring it is clamped securely.
• Reattach the fuel filler neck to the rubber hose, ensuring it is clamped securely.
• Reconnect the harness to the fuel pump or sending unit.
• Refasten the fuel tank straps and tighten them until they stop. Torque the mounting nuts to the specified level (if this information is not available, tighten the nuts with thread locker and then give them an extra turn of approximately 1/8th).
• Realign the fuel filler neck and secure it with the mounting screws or bolts. Reattach the cable for the fuel filler cap.
• Reconnect the vehicle's battery and remove the nine-volt battery saver (if used).
• Check for leaks.

Reattach the fuel tank and reconnect the battery

Once you have finished replacing the fuel level sender, you can begin to reattach the fuel tank and reconnect the battery.

First, you will need to raise the fuel tank back under the vehicle. Wipe out the rubber hose on the fuel tank with a lint-free cloth. Place a new clamp onto the rubber hose and twist the fuel filler neck into the rubber hose. Put the clamp in place and tighten it until the hose will not twist. Allow the fuel filler neck to twist, but do not let the clamp move.

Next, raise the fuel tank up to the vent hose. Attach the vent hose using a new clamp and tighten the clamp until the hose will not twist and turn 1/8 of a turn. Make sure that you do not use the old clamps, as they will not hold tight and may cause a vapor leak.

Now, raise the fuel tank up to align the fuel filler neck to the cutaway. Align the fuel filler neck mounting holes and lower the fuel tank. Tighten the clamp and keep the fuel filler neck from moving.

Then, raise the fuel tank up to the harness. Connect the fuel pump or sending unit harness to the fuel tank connector. Attach the fuel tank straps and tighten them until they stop. Torque the mounting nuts to the specifications on the fuel tank. If you do not know the torque value, you can tighten the nuts 1/8 of a turn more with thread locker.

After that, align the fuel filler neck to the cutaway in the fuel door area. Install the mounting screws or bolts into the neck and secure it tight. Attach the cable of the fuel filler cap to the neck. Screw on the fuel filler cap until it locks in place.

Finally, open the vehicle's hood to reconnect the battery. Remove the nine-volt battery saver from the cigarette lighter, if you used one. Reconnect the ground cable to the battery's negative post. Tighten the battery clamp and ensure that the connection is good.

Now, you can lower the vehicle and remove the wheel chocks. Your 2007 Dodge Charger's fuel level sender replacement is complete.

Test for leaks

To test for leaks in your 2007 Dodge Charger, you can start by looking for any visible signs of leakage. Park your car in a spot and slide a piece of white cardboard underneath the car. This will help you identify any fluids that may be leaking.

If you suspect a fuel leak, do not drive your vehicle as fuel is highly flammable. A fuel leak could be due to a crack or hole in the fuel tank.

If you notice a clear liquid, it is most likely water, possibly from the air conditioning unit, exhaust, or windscreen washers. Coolant is also clear but tends to have a coloured tinge (green, blue, or yellow) and a sweet odour.

A reddish-brown liquid could indicate a transmission fluid leak, while a brown or black liquid is likely engine oil. A leak in red/brown fluid near the power steering reservoir could indicate a power steering fluid leak.

If you notice a brownish puddle under your car, it could be brake fluid, which requires immediate attention as it is very dangerous.

To test for an interior water leak, consider when the leak occurs. If it happens after rain or a car wash, it could be due to a failed weatherstripping seal or blocked sunroof drain. If it only occurs when parked on a slope, it is likely due to a blocked sunroof drain.

You can also perform an instrument panel test to check the fuel gauge and ensure it is working properly. This involves a series of steps with the ignition switch and observing the gauge needles during the test.

Frequently asked questions