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.
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HOMESERVICE MANUALSCHRYSLER2004PT CRUISER TOURING, 2.4 B, AUTOMATICREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 67 (FUEL DELIVERY SYSTEM)FUEL LEVEL SENDING UNIT / SENSORINSTALLATION
2004 Chrysler PT Cruiser Touring, 2.4 B, Automatic
Fuel Level Sending Unit / Sensor: Installation
2004 Chrysler PT Cruiser Touring, 2.4 B, AutomaticSECTION Installation
WARNING: This page is about a different car, the 2004 Dodge Intrepid, 2004 Chrysler Intrepid, 2004 Chrysler Concorde, and 2004 Chrysler 300M. However, it is still accessible from the selected car via links, so may be relevant.
- Insert level sensor wires in bottom of stand-pipe.
- Wrap wires into groove in back of level sensor (Fig 1).
- While feeding wires into standpipe, slide level sensor up into installation channel until it snaps into place. Ensure tab at bottom of sensor locks in place.
- 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 (Figure).
- Install retaining clip on connector.
- Push fuel pump/level sensor connector up into bottom of fuel pump module electrical connector.
- Install fuel pump module. Refer to FUEL PUMP MODULE .
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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.