300M, Concorde, Intrepid, LHS, 1998-2004

Fuel Level Sending Unit/Fuel Pump Module

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Description & Operation



The fuel level sending unit is attached to the side of fuel pump module. The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank. The float arm attached to the sensor moves as the fuel level changes. The fuel level input is used as an input for OBD II. If the fuel level is below 15% of total tank capacity several monitors are disabled. There are diagnostics for the level circuit open and shorted.

Removal & Installation



  1. Remove fuel pump module.
  2.  
  3. Depress the retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector.
  4.  
  5. Remove wire terminal retaining clip from connector. Note the location of terminals for the level sensor wires.
  6.  
  7. Using special tool 7812, or an equivalent, push level sensor signal and ground terminals out of the connector.
  8.  
  9. Insert a screwdriver between the fuel pump module and the top of the level sensor housing. Push level sensor down slightly.
  10.  
  11. Slide level sensor wires through standpipe inside fuel pump module.
  12.  
  13. Slide level sensor out of the channel.
  14.  

To install:

  1. Insert level sensor wires in bottom of stand- pipe.
  2.  
  3. Wrap wires into groove in back of level sensor.
  4.  
  5. While feeding wires into standpipe, slide level sensor up into the channel until it snaps into place. Ensure tab at bottom of sensor locks in place.
  6.  
  7. Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place. Ensure signal and ground wires are installed in the correct position.
  8.  
  9. Install retaining clip on connector.
  10.  
  11. Push fuel pump/level sensor connector up into bottom of fuel pump module electrical connector.
  12.  
  13. Install fuel pump module.

    Click image to see an enlarged view

    Fig.



    Click image to see an enlarged view

    Fig.



    Click image to see an enlarged view

    Fig.



    Click image to see an enlarged view

    Fig.

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