PT Cruiser, 2001 - 2005

Fuel Level Sending Unit/Fuel Pump Module

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Description & Operation



The level sensor is attached to the side of the fuel pump module. The level sensor consists of a float, an arm, and a variable resistor.

Click image to see an enlarged view

Fig.

As the fuel level increases, the float and arm move up. This decreases the sending unit resistance, causing the fuel gauge on the instrument panel to read full. The fuel level sensor (fuel gauge sending unit) sends a signal to the BCM and the BCM sends the signal over the PCI bus circuit to the PCM to indicate fuel level. The purpose of this feature is to prevent a false setting of misfire and fuel system monitor trouble codes if the fuel level is less than approximately 15 percent of its rated capacity. It is also used to send a signal for fuel gauge operation via the PCI bus circuits.Location of Fuel Level Sensor (1) on fuel pump module

Removal & Installation




NOTE
The pump module harness on TOP of flange is not serviceable or removable

  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. Remove the wedge lock from the electrical connector.
  6.  
  7. Using Special Tool C-4334 terminal remover, or equivalent, remove terminals from level sensor connector.
  8.  
  9. Depress the tab and slide the sensor toward the bottom of the fuel pump module.
  10.  
  11. Slide level sensor out of channel in module.
  12.  

To install:

  1. Wrap wires into groove in back of level sensor.
  2.  
  3. 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.
  4.  
  5. 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.
  6.  
  7. Install locking wedge on connector.
  8.  
  9. Push connector up into bottom of fuel pump module electrical connector.
  10.  
  11. Install fuel pump module.

    Click image to see an enlarged view

    Fig.

  12.  

 
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