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 Voyager ECFACTORY OEM SERVICE PROCEDURE
Fuel Level Sending Unit Input Open
NOTE:
After making any repairs, perform BODY VERIFICATION TEST under VERIFICATION TESTS.
- Turn ignition on. Using scan tool, record and erase Body Control Module (BCM) DTCs. Turn ignition off and back on. Wait 15 seconds. Recheck for DTCs. If FUEL LEVEL SENDING UNIT INPUT OPEN resets, go to next step. If FUEL LEVEL SENDING UNIT INPUT OPEN does not reset, conditions necessary to set this DTC are not present at this time. Check for intermittent poor connections or faulty circuits and repair as necessary. Check for any related Technical Service Bulletins (TSBs).
- Turn ignition off. Access and disconnect fuel tank module connector. See FUEL TANK MODULE under REMOVAL & INSTALLATION. Using a test light connected to ground, probe fuel tank module connector terminal No. 3 (Dark Blue/White wire). If test light does not illuminate, go to next step. If test light illuminates, repair short to voltage in Dark Blue/White wire between fuel tank module and BCM connector C3 terminal No. 20. See Figure.
- Using DVOM, measure resistance between ground and fuel tank module connector terminals No. 1 (Black/Orange wire) and No. 2 (Black/Dark Blue wire). If resistance is 5 ohms or less at either terminal, go to next step. If resistance is greater than 5 ohms at both terminals, repair open in suspect circuit that measured greater than 5 ohms.
- Turn ignition on. Using scan tool, select BODY CONTROL MODULE then SENSORS. Monitor FUEL SENSOR voltage. Connect a jumper between fuel tank module connector terminals No. 1 (Black/Orange wire) and No. 3 (Dark Blue/White wire). If voltage is greater than 0.5 volt, go to next step. If voltage is 0.5 volt or less, replace fuel tank module fuel level sending unit. See FUEL TANK MODULE under REMOVAL & INSTALLATION.
- Turn ignition off. Locate and disconnect BCM connector C3. See COMPONENT LOCATIONS . See Figure. Using DVOM, measure resistance of Dark Blue/White wire between BCM connector C3 terminal No. 20 and fuel tank module connector terminal No. 3. If resistance is 5 ohms or less, replace BCM. See BODY CONTROL MODULE under REMOVAL & INSTALLATION. If resistance is greater than 5 ohms, repair open in Dark Blue/White wire.
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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