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.
2002 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 the ignition on. With the DRBIII, erase DTC's. Cycle the ignition off and then back on. With the DRBIII, read DTCs. If the DRBIII does not display FUEL LEVEL SENSOR OPEN, the test is complete. DTC is intermittent. Road test the vehicle and recheck for DTCs. If the code returns, rerun this test. Refer to any Technical Service Bulletins (TSB) that may apply. Inspect related harness and connectors. If the DRBIII displays FUEL LEVEL SENSOR OPEN, go to the next step.
- Turn the ignition off. Disconnect the fuel pump module harness connector. See Fig 1. Measure the voltage between the fuel level sensor signal circuit and ground. If there is any voltage present, repair the fuel level sensor signal circuit for a short to voltage. If there is no voltage present, go to the next step.
- Turn the ignition off. Disconnect the fuel pump module harness connector. Check connectors, clean/repair as necessary. Connect a jumper wire between the fuel level sensor signal circuit and ground. Turn the ignition on. With the DRBIII in SENSORS, read the fuel sender volts. If the DRBIII displays 0 (zero) volts, go to the next step. If the DRBIII does not display 0 (zero) volts, repair the fuel level sensor signal circuit for an open.
- Turn the ignition off. Disconnect the fuel pump module harness connector. Check connectors, clean/repair as necessary. Measure the resistance between ground and the fuel level sensor ground circuit. If the resistance is below 5.0 ohms, go to next step. If the resistance is above 5.0 ohms, repair the fuel pump module ground circuit for an open.
- Turn the ignition off. Disconnect the fuel pump module harness connector. Check connectors, clean/repair as necessary. Measure the resistance of the fuel level sensor between the sensor signal circuit pin and the sensor ground circuit pin. Is the resistance is above 1100 ohms, replace the fuel level sender. See FUEL LEVEL SENSOR under FUEL SYSTEMS in appropriate REMOVAL, OVERHAUL & INSTALLATION article in ENGINE PERFORMANCE. If the resistance is below 1100 ohms, replace the instrument cluster. See INSTRUMENT CLUSTER under REMOVAL & INSTALLATION in appropriate ANALOG INSTRUMENT PANELS 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.
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