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.
2001 Chrysler PT Cruiser Base, AutomaticFACTORY OEM SERVICE PROCEDURE
Fuel Level Sensor Open
NOTE:
After making any repairs, perform BODY VERIFICATION TEST under VERIFICATION TESTS.
- Turn ignition off. Connect scan tool to Data Link Connector (DLC). DLC is located on bottom of instrument panel, to left of brake pedal. See Figure. Clear DTCs. Turn ignition off. Turn ignition on. Wait 30 seconds. Using scan tool, check DTCs. If scan tool displays FUEL LEVEL SENSOR OPEN, go to next step. If no DTCs are set, no problem is found at this time. Test is complete. Road test vehicle and recheck DTCs.
- Turn ignition off. Disconnect Light Gray 4-pin fuel pump module harness connector, located at fuel tank. Using ohmmeter, measure resistance between ground and harness connector terminals No. 1 (Black wire) and No. 2 (Black/Light Green wire). See Fig 1. If resistance is less than 5 ohms on both circuits, go to next step. If resistance is 5 ohms or more on either circuit, repair open or poor connection(s).
- Remove instrument cluster. See ANALOG INSTRUMENT PANELS - PT CRUISER article. Turn ignition on. Measure voltage between instrument cluster harness connector C2 terminal No. 9 (Dark Blue wire) and ground. See Figure. If no voltage exists, go to next step. If any voltage exists, repair short to voltage on Dark Blue wire.
- Turn ignition off. Measure resistance between fuel pump module terminals No. 2 (sensor ground) and No. 3 (sensor signal). If resistance is 1060 ohms or less, go to next step. If resistance is more than 1060 ohms, replace fuel level sensor. Fuel level sensor is mounted on fuel pump module. See FUEL PUMP MODULE under REMOVAL, OVERHAUL & INSTALLATION - CARS article in ENGINE PERFORMANCE.
- Connect a jumper wire between instrument cluster harness connector C2 terminal No. 9, fuel level sensor signal circuit (Dark Blue wire) and ground. Using ohmmeter, check resistance between fuel pump connector terminal No. 3, fuel level sensor signal circuit (Dark Blue wire) and ground. If resistance is 5 ohms or more, repair open Dark Blue wire. If resistance is less than 5 ohms, replace instrument cluster. See ANALOG INSTRUMENT PANELS - PT CRUISER article.
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.