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Home >> Dodge and Ram >> 2009 >> Caliber SRT-4 >> Repair and Diagnosis >> Engine Performance >> System >> DTCS P0443 To P0533 >> P0461-Fuel Level Sensor 1 Performance >> Diagnostic Test

Diagnostic Test

  1. DIAGNOSTIC TROUBLE CODE (DTC) IS ACTIVE 
    1. Turn the ignition on.
    2. Using the scan tool, read DTCs and review the DTC environmental information.

      Is the good trip counter greater than 0?

      Yes 

      • Test complete, the condition or conditions that originally set this DTC are not present at this time. Using the wiring diagrams as a guide, check all related splices and connectors for signs of water intrusion, corrosion, pushed out or bent terminals, and correct pin tension.
      • Perform the CHECKING FOR AN INTERMITTENT DTC diagnostic procedure. See DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure .

      No 

      • Go to step  2
  2. EXTERIOR FUEL TANK DAMAGE 
    1. Inspect the exterior of the fuel tank for any damage that may restrict the movement of the fuel level sensor floats.

      Were any problems found?

      Yes 

      No 

      • Go to step  3
  3. FUEL PUMP MODULE WIRING AND CONNECTORS 
    1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Fuel Pump Module harness connector and the Instrument Cluster (CCN).
    2. Look for any chafed, pierced, pinched or partially broken wires.
    3. Look for broken, bent, pushed out or corroded terminals.
    4. Perform any Technical Service Bulletins that may apply.

      Were any problems found?

      Yes 

      No 

      • Go to step  4
  4. (N4) FUEL LEVEL SIGNAL 1 CIRCUIT VOLTAGE 
    Fig 1: Checking Fuel Level Signal Circuit
    GC0103585Courtesy of CHRYSLER LLC
    1. Turn the ignition off.
    2. Disconnect the Fuel Pump Module harness connector.
    3. Turn the ignition on.
    4. Using the scan tool, read the Fuel Level Sensor 1 circuit voltage.
      NOTE: The sensor voltage should be approximately 5.0 Volts (plus or minus.1 of a Volt) with the connector disconnected.
    5. Turn the ignition off.
    6. Connect a jumper wire between ground and the (N4) Fuel Level Signal 1 circuit in the Fuel Pump Module harness connector.
    7. Turn the ignition on.
    8. Using the scan tool, read the Fuel Level Sensor 1 circuit voltage.
      NOTE: The sensor voltage should be approximately 0.0 Volts (plus or minus.1 of a Volt) with the jumper wire in place.

      Does the scan tool display the voltage as described above?

      Yes 

      • Go to step  5

      No 

      • Go to step  8
  5. (Z965/Z906) GROUND CIRCUIT OPEN OR HIGH RESISTANCE 
    Fig 2: Checking Ground Circuit
    GC0103586Courtesy of CHRYSLER LLC
    1. Turn the ignition off.
    2. Measure the resistance between ground and the (Z965/Z906) Ground circuit in the Fuel Pump Module harness connector.

      Is the resistance below 5.0 Ohms?

      Yes 

      • Go to step  6

      No 

  6. FUEL TANK WIRING HARNESS INSPECTION 
    WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury.
    1. Remove the fuel tank in accordance with the Service Information.
    2. Inspect the wiring and connectors between the Fuel Pump Module harness connector and both Fuel Level Sensors.
    3. Look for any chafed, pierced, pinched or partially broken wires.
    4. Look for broken, bent, pushed out or corroded terminals.

      Were any problems found?

      Yes 

      No 

      • Go to step  7
  7. FUEL LEVEL SENSOR 1 INSPECTION 
    1. Remove the Fuel Level Sensor 1 sensor.
    2. Inspect the Fuel Level Sensor 1 and the inside of the fuel tank for any condition that would restrict the movement of the fuel level sensor float.

      Were any problems found?

      Yes 

      No 

  8. (N4) FUEL LEVEL SIGNAL 1 CIRCUIT SHORTED TO VOLTAGE 
    Fig 3: Checking Fuel Level Signal Circuit
    GC0103587Courtesy of CHRYSLER LLC
    1. Turn the ignition off.
    2. Disconnect the Instrument Cluster (CCN) C2 harness connector.
    3. Turn the ignition on.
    4. Measure the voltage of the (N4) Fuel Level Signal 1 circuit in the Fuel Level Sensor 1 harness connector.

      Is there any voltage present?

      Yes 

      No 

      • Go to step  9
  9. (N4) FUEL LEVEL SIGNAL 1 CIRCUIT SHORTED TO GROUND 
    Fig 4: Checking Fuel Level Signal 1 Circuit
    GC0103588Courtesy of CHRYSLER LLC
    1. Turn the ignition off.
    2. Measure the resistance between ground and the (N4) Fuel Level Signal 1 circuit in the Fuel Level Sensor 1 harness connector.

      Is the resistance above 100 Ohms?

      Yes 

      • Go to step  10

      No 

  10. (N4) FUEL LEVEL SIGNAL 1 CIRCUIT OPEN OR HIGH RESISTANCE 
    Fig 5: Checking Fuel Level Signal 1 Circuit
    GC0103589Courtesy of CHRYSLER LLC
    1. Measure the resistance of the (N4) Fuel Level Signal 1 circuit between the Fuel Pump Module harness connector and the Instrument Cluster (CCN) C2 harness connector.

      Is the resistance below 5.0 Ohms?

      Yes 

      • Go to step  11

      No 

  11. INSTRUMENT CLUSTER (CCN) 
    1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Fuel Pump Module and the Instrument Cluster (CCN).
    2. Look for any chafed, pierced, pinched or partially broken wires.
    3. Look for broken, bent, pushed out or corroded terminals.
    4. Perform any Technical Service Bulletins that may apply.

      Were any problems found?

      Yes 

      No 

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