Replacing Fuel Level Sensor In 2007 Town And Country

The fuel level sending unit is located in the fuel tank of a car and constantly sends a signal indicating the amount of fuel that remains. When it fails, the fuel gauge will also fail to operate, and the check engine light may illuminate. The fuel level sensor will usually have a mechanical arm extending to the top of the fuel inside the tank, floating on top of the fuel. As the arm moves down, the signal strength from the sending unit decreases, and this information is sent to the fuel level gauge for the driver's awareness. In this article, we will discuss how to replace the fuel level sensor in a 2007 Town and Country.

The fuel level sending unit is located in the fuel tank

The fuel level sending unit is located inside the fuel tank of your 2007 Town and Country. This is where the constant signal that indicates the amount of fuel remaining in the tank is sent from.

In most systems, the fuel level sensor will have a mechanical arm extending to the top of the fuel inside the tank. It will float on the top of the fuel, and as the arm moves down, the signal strength from the sending unit decreases. That information is sent to the fuel level gauge in your dashboard. When the arm gets low enough, the light on the dashboard will be turned on, alerting you to stop for fuel.

When the fuel level sending unit fails, the fuel gauge will not operate, and the check engine light may illuminate. The on-board diagnostic (OBD) trouble codes stored will be relative to the fuel level sensor.

To replace the fuel level sending unit, you must remove it from the fuel tank. There may be a service access panel underneath the trunk or back seat that you can use to access the unit. However, in some cases, you may need to remove the fuel tank to access the unit. The unit is typically unbolted from the fuel tank and disconnected from the fuel and electrical connectors.

The average cost for a Chrysler Town and Country Fuel Level Sending Unit Replacement is between $1,955 and $2,098. Labor costs are estimated between $121 and $152, while parts are priced between $1,835 and $1,946.

The fuel level sensor has a mechanical arm that extends to the top of the fuel

The fuel level sensor's mechanical arm is an integral part of the fuel system, providing critical information to the driver about the amount of fuel in the tank. This arm physically extends to the top of the fuel, floating on its surface, and its movement is directly linked to the signal strength from the sending unit. As the arm moves down with the decreasing fuel level, the signal strength weakens, and this information is relayed to the fuel level gauge. This mechanism ensures that the driver is aware of the fuel level at all times and receives a prompt to refuel when the arm reaches a certain low point, triggering the dashboard light to turn on.

The fuel level sensor's mechanical arm is a crucial component for accurate fuel gauge readings. Its design allows it to float on the fuel's surface, ensuring precise measurements. This arm is typically made of materials like stainless steel or galvanized steel and is connected to the sending unit, which generates the signal based on the arm's position.

While the fuel level sensor's mechanical arm is a simple yet ingenious design, it requires proper maintenance to ensure its accuracy and longevity. Over time, fuel contaminants, debris, or corrosion can impact the arm's movement, leading to incorrect fuel gauge readings. Regular cleaning and inspection of the fuel tank and sensor arm are essential to prevent such issues.

In some vehicles, the fuel level sensor's mechanical arm may be difficult to access, requiring the removal of the fuel tank for maintenance or replacement. This process can be complex and should be performed by individuals with the necessary knowledge and skills to handle fuel and electrical systems safely. However, for those with the right expertise, adjusting or replacing the sensor arm can help ensure the fuel gauge's accuracy and provide peace of mind to drivers.

The fuel level sensor's mechanical arm is a testament to automotive engineering's attention to detail. Its function may be subtle, but it plays a vital role in keeping drivers informed about their vehicle's fuel status, ultimately contributing to a safer and more reliable driving experience.

The fuel gauge will fail to operate when the fuel level sending unit fails

The fuel level sending unit is located in the fuel tank and is responsible for sending a constant signal to the fuel gauge, indicating the amount of fuel that remains. When the sending unit fails, the fuel gauge will fail to operate, and the vehicle may be at risk of running out of fuel.

The sending unit is made up of a float, a metal rod or arm, and a variable resistor. The float is made of a buoyant composite or foam and floats on top of the fuel in the tank. The float is connected by a thin metal rod to a contact inside the variable resistor. The variable resistor receives power via a small coil from the vehicle's battery, which is used as the baseline signal. As the fuel level drops, the position of the arm and float shift, moving the resistor, which controls the display on the gauge.

There are several symptoms of a faulty fuel level sending unit. One of the first signs is erratic behaviour of the fuel gauge, such as sudden changes in position or inaccurate readings. Another common symptom is the fuel gauge being stuck on empty, which can be caused by the float breaking or becoming separated from the arm. A less common issue is the gauge being stuck on full, which is caused by a faulty fuel gauge resistor sending a constant full voltage to the instrument cluster.

If you suspect a problem with the fuel level sending unit, it is recommended to have the vehicle inspected by a professional technician. The repair cost for a fuel level sending unit replacement can vary depending on the vehicle, but it is generally an expensive repair, ranging from $1,955 to $2,098.

The fuel level sending unit must be removed from the fuel tank

To replace the fuel level sending unit, you will first need to remove it from the fuel tank. This process can vary depending on the specific vehicle, but in most cases, there are two common methods for accessing the fuel level sending unit.

One method is to locate and access the service access panel, which is usually found underneath the trunk lining or back seat. This provides a direct route to the fuel level sending unit without needing to remove the fuel tank.

However, if there is no service access panel, the second method involves removing the fuel tank to access the unit. This is a more complex process and may require assistance due to the weight and size of the fuel tank. It is crucial to exercise caution when handling the fuel tank to prevent injury or damage to the vehicle.

Once you have gained access to the fuel level sending unit, the next steps are to unbolt it from the fuel tank and disconnect it from the fuel and electrical connectors. It is standard procedure for technicians to disconnect the battery before accessing any electrical components, such as the fuel pump.

After the old unit has been removed, it is recommended to compare its movement with that of the new fuel level sending unit. Adjustments to the arm may be necessary to ensure the proper fuel level is displayed on the gauge.

The fuel tank may need to be removed to access the fuel sending unit

To replace the fuel level sensor on a 2007 Town and Country, you may need to remove the fuel tank to access the fuel sending unit. This is because the fuel sending unit is located inside the fuel tank and attached to the fuel pump.

Lowering the Fuel Level and Disconnecting the Battery

• Firstly, lower the fuel level in the tank as much as possible to make the job easier.
• Disconnect the negative battery cable.

Raising the Vehicle and Removing the Fuel Filler Cap Cable

• Raise the vehicle using a jack and place wheel chocks around the front tires. Engage the parking brake.
• Remove the fuel filler cap cable from the fuel neck and place it aside. Open the fuel door to access the fuel filler neck.

Removing Mounting Screws and Lowering the Fuel Tank

• Remove the mounting screws or bolts attached to the cutaway.
• Locate the fuel tank and lower it slightly. Use a transmission jack or similar to support the tank and loosen and remove the straps.
• Disconnect the harness from the connector by reaching up to the top of the fuel tank.

Creating Clearance and Removing the Fuel Filler Neck

• Lower the fuel tank further to access the vent hose. Remove the clamp and small vent hose for more clearance.
• Remove the fuel filler neck by twisting it out of the rubber hose and guiding it out of the area.

Removing the Fuel Tank and Inspecting the Rubber Hose

• Remove the fuel tank from the vehicle, ensuring you transfer any remaining fuel to a safe container.
• Inspect the rubber hose for any cracks and replace it if necessary.

At this stage, the fuel tank has been successfully removed, and you can now access the fuel sending unit for replacement. Remember to clean the harness and connector, and ensure that the vehicle is on a level surface to prevent any accidental movement.

Frequently asked questions