Breeze, Cirrus, Sebring Convertible and Sedan, Stratus Sedan, 1999-2005

Fuel Level Sending Unit/Fuel Pump Module

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Description & Operation



The fuel gauge 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% or above 85% of total tank capacity several monitors are disabled. There are diagnostics for the level circuit open and shorted.

The fuel gauge 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% or above 85% 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 retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector.
  4.  
  5. Pull off locking wedge. Using a small screwdriver, lift the locking finger away from terminal and push level sensor and ground terminals out of connector.
  6.  
  7. Push level sensor signal and ground terminals out of the connector. Use screwdriver to move locking tab on level sensor and move level sensor down channel to remove.
  8.  
  9. Slide level sensor wires through opening fuel pump module.
  10.  
  11. Slide level sensor out of channel in 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.

  12.  

To Install:

  1. Insert level sensor wires into bottom of opening in module.
  2.  
  3. Wrap wires into groove in back of level sensor.
  4.  
  5. While feeding wires into guide grooves, slide level sensor up into 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 locking wedge on connector.
  10.  
  11. Push connector up into bottom of fuel pump module electrical connector.
  12.  
  13. Install fuel pump module.

    Click image to see an enlarged view

    Fig.

  14.  

  1. Remove fuel pump module.
  2.  
  3. Depress retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector.
  4.  
  5. Pull off locking wedge. Using a small screwdriver, lift the locking finger away from terminal and push level sensor and ground terminals out of connector.
  6.  
  7. Push level sensor signal and ground terminals out of the connector. Use screwdriver to move locking tab on level sensor and move level sensor down channel to remove.
  8.  
  9. Slide level sensor wires through opening fuel pump module.
  10.  
  11. Slide level sensor out of channel in 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.

  12.  

To Install:

  1. Insert level sensor wires into bottom of opening in module.
  2.  
  3. Wrap wires into groove in back of level sensor.
  4.  
  5. While feeding wires into guide grooves, slide level sensor up into 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 locking wedge on connector.
  10.  
  11. Push connector up into bottom of fuel pump module electrical connector.
  12.  
  13. Install fuel pump module.

    Click image to see an enlarged view

    Fig.

  14.  

 
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