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Home >> Chrysler >> 2006 >> PT Cruiser Base, 2D Convertible, Standard >> Repair and Diagnosis >> Engine Performance >> Testing & Diagnosis >> 1.6L Engine - DTCS P0303 To P0629 >> Diagnosis And Testing >> P0461-Fuel Level Unit No Change Over Time >> Diagnostic Test

Diagnostic Test

  1. 1)  GOOD TRIP INDICATED 
    NOTE: Diagnose P0462  or P0463  first, if set along with P0461  .

    Turn the ignition on.

    With the scan tool, read DTCs.

    Does the Good Trip Indicator display NO? 

    Yes 

    1. Go To  2).

    No 

    1. Refer to the INTERMITTENT CONDITION diagnostic procedure.
    2. Perform the POWERTRAIN VERIFICATION TEST. (Refer to STANDARD PROCEDURE - POWERTRAIN VERIFICATION TEST) .
  2. 2)  VISUALLY INSPECT FUEL TANK 

    Visually inspect the Fuel Tank for damage that may restrict the Fuel Sending Unit float from moving.

    Is the Fuel Tank OK? 

    Yes 

    1. Go To  3).

    No 

    1. Replace the Fuel Tank as necessary.
    2. Perform the POWERTRAIN VERIFICATION TEST. (Refer to STANDARD PROCEDURE - POWERTRAIN VERIFICATION TEST) .
  3. 3)  (N4) FUEL LEVEL SENSOR SIGNAL CIRCUIT SHORTED TO GROUND 
    Fig 1: MEASURING RESISTANCE OF THE FUEL LEVEL SENSOR SIGNAL CIRCUIT
    GC0041912Courtesy of DAIMLERCHRYSLER CORP.

    Turn the ignition off.

    Disconnect the Fuel Pump Module harness connector.

    Measure the resistance of the (N4) Fuel Level Sensor Signal circuit in the Fuel Pump Module harness connector to ground.

    Is the resistance below 100 ohms? 

    Yes 

    1. Repair the short to ground in the (N4) Fuel Level Sensor Signal circuit.
    2. Perform the POWERTRAIN VERIFICATION TEST. (Refer to STANDARD PROCEDURE - POWERTRAIN VERIFICATION TEST) .

    No 

    1. Go To  4).
  4. 4)  (N4) FUEL LEVEL SENSOR SIGNAL CIRCUIT OPEN 
    Fig 2: MEASURING RESISTANCE OF THE FUEL LEVEL SENSOR SIGNAL CIRCUIT
    GC0041913Courtesy of DAIMLERCHRYSLER CORP.

    Disconnect the Instrument Cluster harness connector.

    Measure the resistance of the (N4) Fuel Level Sensor Signal circuit between the Fuel Pump Module harness connector and the Instrument Cluster harness connector.

    Is the resistance below 5.0 ohms? 

    Yes 

    1. Go To  5).

    No 

    1. Repair the open in the (N4) Fuel Level Sensor Signal circuit.
    2. Perform the POWERTRAIN VERIFICATION TEST. (Refer to STANDARD PROCEDURE - POWERTRAIN VERIFICATION TEST) .
  5. 5)  (Z904) GROUND CIRCUIT OPEN 
    Fig 3: MEASURING RESISTANCE OF THE GROUND CIRCUIT
    GC0041914Courtesy of DAIMLERCHRYSLER CORP.

    Measure the resistance of the (Z904) Ground circuit in the Fuel Pump Module harness connector to ground.

    Is the resistance below 5.0 ohms? 

    Yes 

    1. Go To  6).

    No 

    1. Repair the open in the (Z904) Ground circuit.
    2. Perform the POWERTRAIN VERIFICATION TEST. (Refer to STANDARD PROCEDURE - POWERTRAIN VERIFICATION TEST) .
  6. 6)  INTERNAL INSPECTION OF THE FUEL TANK 
    WARNING: The fuel system is under a constant pressure even with the engine off. Before opening the fuel system the fuel pressure must be release. Relieve the fuel pressure in accordance with the service information.

    Remove the Fuel Tank in accordance with the Service Information.

    Remove the Fuel Pump Module.

    Visually inspect the inside of the Fuel Tank for any obstructions or deformities.

    Inspect the Fuel Pump Module Float arm for damage.

    Were any problem found? 

    Yes 

    1. Repair or replace as necessary.
    2. Perform the POWERTRAIN VERIFICATION TEST. (Refer to STANDARD PROCEDURE - POWERTRAIN VERIFICATION TEST) .

    No 

    1. Go To  7).
  7. 7)  FUEL LEVEL SENSOR 

    If there are no possible causes remaining, view repair. 

    Repair 

    1. Replace the Fuel Level Sensor.
    2. Perform the POWERTRAIN VERIFICATION TEST. (Refer to STANDARD PROCEDURE - POWERTRAIN VERIFICATION TEST) .
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