1. Safety First:
* Disconnect the negative battery cable. This prevents accidental sparks near flammable fuel.
* Ventilate the area. Work in a well-ventilated space, ideally outdoors. Fuel vapors are dangerous.
* Gather your tools. You'll need:
* Socket wrench set (metric)
* Screwdrivers (Phillips and flathead)
* Fuel line disconnect tool (important to avoid leaks)
* New fuel sending unit
* Shop rags or absorbent material
* Safety glasses
* Possibly a fuel pump removal tool (depending on the design)
* Jack and jack stands (to safely lift the vehicle)
* Consult a repair manual: A Chilton's or Haynes repair manual specific to your year and model Stratus is highly recommended. It will provide detailed diagrams and instructions tailored to your vehicle.
2. Access the Fuel Tank:
* Lower the vehicle: Safely lift and support the rear of the vehicle using a jack and jack stands.
* Remove the rear seat: This is usually done by removing the seatback and/or the seat cushion. Consult your repair manual for the specific procedure. There may be clips, bolts, or latches involved.
* Locate the access panel: The fuel tank usually has an access panel, sometimes underneath the vehicle, sometimes within the trunk area after the seat is removed. The access panel provides access to the fuel pump and sending unit. You may need to remove some trim pieces to get to this panel.
3. Replace the Fuel Sending Unit:
* Disconnect the fuel lines: Use the fuel line disconnect tool to safely disconnect the fuel lines leading to and from the fuel pump module. Have absorbent material ready to catch any spilled fuel.
* Disconnect the electrical connector: Unplug the electrical connector from the fuel sending unit.
* Remove the fuel pump assembly (if necessary): Some Stratus models require removing the entire fuel pump assembly to access the sending unit. This often involves unbolting the assembly and possibly using a fuel pump removal tool.
* Replace the fuel sending unit: Carefully remove the old sending unit and install the new one, ensuring a tight and secure fit.
* Reassemble everything: Reinstall the fuel pump assembly (if removed), reconnect the electrical connector, and reconnect the fuel lines securely. Double-check that all connections are tight and secure to prevent leaks.
* Raise the vehicle: Carefully lower the vehicle from the jack stands.
* Reinstall the rear seat: Reassemble the rear seat components.
4. Testing:
* Reconnect the negative battery cable.
* Start the vehicle: Check for fuel leaks. Check the fuel gauge to ensure it's functioning correctly.
Important Notes:
* Fuel is highly flammable. Exercise extreme caution throughout the entire process.
* If you're uncomfortable with any part of this procedure, take your Stratus to a qualified mechanic. This is not a beginner-level repair.
* The specific steps may differ slightly based on your model year. Always consult a repair manual specific to your vehicle.
Failure to properly follow these steps could lead to injury or damage to your vehicle. If you lack experience with car repairs, it's best to leave this job to a professional.
