Low fuel light on, tank is full

Tiny
JERRY BRIGHT
  • MEMBER
  • 2009 DODGE CALIBER
  • 1.8L
  • MANUAL
  • 167,041 MILES
Hi, can anyone help me out here? L have filled up my fuel tank but l still have my low fuel light on and my fuel gauge is not reading. But the car runs very well.
Thursday, May 10th, 2018 AT 7:19 PM

1 Reply

Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,772 POSTS
Hi Jerry and thanks for using 2CarPros. Com. Chances are, your problem is related to the fuel level sending unit; although, the interment cluster plays a part in the gauge's function. I have to be honest, 99% of the time, it is the sending unit rheostat that is bad and the sending unit needs replaced. The fuel gauge is controlled by the instrument cluster circuit board based upon cluster programming and a hard wired input received by the cluster from the fuel level sending unit on the module in the fuel tank. With that being said, and on a brighter note, the pump/sending unit on your vehicle is accessible without removing the tank. Here are the directions from all data for removal. Additionally I attached several pictures which are related to removal and replacement.

FUEL PUMP MODULE - REMOVAL
REMOVAL

WARNING: Risk of injury to eyes and skin from contact with fuel, Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Failure to comply may result in serious or fatal injury.

Perform Fuel System Pressure Release procedure.
Remove the air cleaner lid, disconnect the inlet air temperature sensor and makeup air hose.
Remove the negative battery cable.
Remove the rear seat cushion.

Remove plastic cover.

Clean top of tank to remove loose dirt and debris.
Use special tool #9340 to remove left side module lock ring.

Note the fuel pump location on the top of the fuel tank.
NOTE: The pump has to be properly located to the tank for the fuel gauge to work properly.

Pull module up out of fuel tank, make sure that you do not spill fuel inside of vehicle.

Drain fuel from fuel pump module. Do not spill fuel in interior of vehicle.

Here are the directions for replacement.

FUEL PUMP MODULE - INSTALLATION
INSTALLATION
NOTE: The pump has to be properly located to the tank for the fuel gauge to work properly.

Wipe seal area of tank clean. Place a new seal between the tank threads and the pump module opening.

Install module.

Position fuel pump module in tank. Make sure the alignment tab lines up on the fuel tank and pump module for Gas or Diesel fuel tanks.

While holding the pump module in position, install lock ring and use special tool Spanner Wrench #9340 to tighten lock ring.

Install plastic cover.

Install rear cushion.

Install the negative battery cable.
Install the air cleaner lid, connect the inlet air temperature sensor and makeup air hose.
Fill fuel tank with clean fuel.

I hope this helps.

Take care,
Joe
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Saturday, May 12th, 2018 AT 9:49 PM

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