Chrysler Stratus Convertible. Manual — part 24
FUEL LEVEL SENSOR
REMOVAL
Remove fuel pump module. Refer to Fuel Pump
Module in this section.
(1) Depress retaining tab and remove the fuel
pump/level sensor connector from the BOTTOM of
the fuel pump module electrical connector (Fig. 18).
NOTE: The pump module harness on TOP of flange
is not serviceable or removable.
(2) Using Special Tool C-4334 terminal remover or
equivalent, remove terminals from level sensor con-
nector (Fig. 19).
(3) Insert a screwdriver between the fuel pump
module and the top of the level sensor housing (Fig.
20). Push level sensor down slightly.
(4) Slide level sensor wires through opening fuel
pump module (Fig. 21).
(5) Slide level sensor out of channel in module.
INSTALLATION
(1) Insert level sensor wires into bottom of opening
in module.
(2) Wrap wires into groove in back of level sensor
(Fig. 22).
(3) While feeding wires into guide grooves, slide
level sensor up into channel until it snaps into place
(Fig. 23). Ensure tab at bottom of sensor locks in
place.
Fig. 18 Fuel Pump/Level Sensor Electrical
Connector
1 – ELECTRICAL CONNECTOR
2 – RETAINING TABS
Fig. 19 Terminal Removal Tool
1 – TERMINAL REMOVAL TOOL
2 – FUEL LEVEL SENSOR CONNECTOR
Fig. 20 Loosening Level Sensor
1 – PRY AGAINST LEVEL SENSOR
2 – LEVEL SENSOR
Fig. 21 Level Sensor Removal/Installation
1 – OPENING IN MODULE
2 – FUEL LEVEL SENSOR
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FUEL SYSTEM
14 - 13
REMOVAL AND INSTALLATION (Continued)
(4) 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
(Fig. 24).
(5) Install locking wedge on connector.
(6) Push connector up into bottom of fuel pump
module electrical connector.
(7) Install fuel pump module. Refer to Fuel Pump
Module in this section.
FUEL RAIL—2.0L
REMOVAL
(1) Disconnect
negative
cable
from
auxiliary
jumper terminal.
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE SERVICING THE VEHICLE.
(2) Release fuel system pressure. Refer to Fuel
System Pressure Release procedure in this section.
WARNING: WRAP SHOP TOWELS AROUND HOSE
TO CATCH ANY GASOLINE SPILLAGE.
(3) Disconnect fuel supply tube from rail. Refer to
Quick-Connect Fittings in this section.
(4) Disconnect electrical connectors from fuel injec-
tors (Fig. 25).
(5) Remove fuel rail mounting screws.
(6) Lift rail off of intake manifold. Cover the fuel
injector openings in the intake manifold.
(7) Remove injectors.
INSTALLATION
(1) Install injectors.
(2) Apply a light coating of clean engine oil to the
O-ring on the nozzle end of each injector.
(3) Insert fuel injector nozzles into openings in
intake manifold. Seat the injectors in place. Tighten
fuel rail mounting screws to 22.5 N·m
6 3 N·m
(200
630 in. lbs.).
(4) Attach electrical connectors to fuel injectors.
(5) Connect fuel supply tube to fuel rail. Refer to
Quick Connect Fittings in this section.
(6) Connect negative cable to auxiliary jumper ter-
minal.
Fig. 22 Groove in Back Side of Level Sensor
1 – WRAP WIRES IN GROOVE
2 – REAR VIEW OF LEVEL SENSOR
Fig. 23 Installation Channel
1 – CHANNEL FOR LEVEL SENSOR
2 – PUMP MODULE
Fig. 24 Fuel/Pump/Level Sensor Electrical
Connector
1 – PUMP GROUND
2 – LEVEL SENSOR GROUND
3 – FUEL PUMP SUPPLY
4 – LEVEL SENSOR SIGNAL
14 - 14
FUEL SYSTEM
JX
REMOVAL AND INSTALLATION (Continued)
(7) Use the DRB scan tool ASD Fuel system test to
pressurize the the fuel system. Check for leaks.
FUEL INJECTORS
REMOVAL
(1) Remove the negative battery cable.
(2) Remove fuel rail. Refer to appropriate Fuel
Rail Removal in this section.
(3) Remove fuel injector (Fig. 26).
(4) Pull injector out of fuel rail. Replace fuel injec-
tor O-rings.
INSTALLATION
(1) Install injector to fuel rail.
(2) Install fuel injector clip.
(3) Install fuel rail refer to the Fuel Rail installa-
tion in this section.
(4) Install the negative battery cable.
(5) Use the DRB scan tool ASD Fuel system test to
pressurize the the fuel system. Check for leaks.
FUEL TANK
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE SERVICING THE VEHICLE.
REMOVAL
(1) Release fuel system pressure. Refer to Fuel
Pressure Release Procedure in this section.
(2) Disconnect
negative
cable
from
auxiliary
jumper terminal.
(3) Remove lower rear seat cushion, disconnect
pump wiring jumper from main body harness. Locate
body grommet for jumper near base of rear seat.
Push grommet out and feed jumper completely
through hole in body.
(4) Remove fuel cap slowly to release tank pres-
sure.
(5) With vehicle on a hoist, drain fuel from tank.
Support fuel tank with a support such as a transmis-
sion jack stand.
(6) Position a fuel approved container, with a
capacity of at least 16 gallons, under the drain plug
located on the bottom left edge of the tank.
CAUTION: Use
a
Back-Up
wrench
on
tank
to
remove drain plug.
(7) Remove drain plug and allow fuel to drain (Fig.
27).
WARNING: DRAIN PLUG MUST BE INSTALLED AT
THIS TIME AS THERE WILL BE 1 TO 2 GALLONS
OF FUEL LEFT IN THE TANK.
Fig. 25 Fuel Rail and Injectors
1 – FUEL SUPPLY LINE
2 – FUEL LINE QUICK-CONNECTS
3 – IGNITION COIL
4 – FUEL RAIL
5 – FUEL INJECTOR
Fig. 26 Fuel Injector Clip—2.5L Engine
1 – FUEL RAIL
2 – FUEL INJECTOR
3 – INJECTOR CLIP
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FUEL SYSTEM
14 - 15
REMOVAL AND INSTALLATION (Continued)
(8) When tank is no longer draining, install drain
plug. Tighten plug to 32 in. lbs.
WARNING: There may be fuel in the fill tube.
Remove hose carefully to reduce fuel splash.
(9) Disconnect fuel tank from rubber fill hose (Fig.
28).
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
(10) Remove bolts and fuel tank straps. Passenger
side first.
(11) Lower fuel tank and remove the EVAP line
and recirculation line (Fig. 29).
(12) Remove vacuum line from LDP.
(13) Disconnect fuel lines from fuel pump module.
These are quick connect fittings (Fig. 30).
(14) Remove hoses from EVAP canister.
Fig. 27 Fuel Tank Drain Plug
1 – FUEL TANK DRAIN PLUG
Fig. 28 Fuel Filler Hose Clamp
1 – FUEL FILLER HOSE
2 – HOSE CLAMP
3 – FUEL TANK INLET
4 – REAR CROSS MEMBER
Fig. 29 Evap Components
1 – LDP FILTER
Fig. 30 Fuel Tank Removal
1 – FUEL FILTER
2 – FUEL TANK
3 – FUEL PUMP MODULE
4 – FUEL TANK VAPOR LINE
14 - 16
FUEL SYSTEM
JX
REMOVAL AND INSTALLATION (Continued)
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