Diagnostic Test

WARNING: This page is about a different car, the 2009 Dodge Caliber. However, it is still accessible from the selected car via links, so may be relevant.

DIAGNOSTIC TROUBLE CODE (DTC) IS ACTIVE
1. Start the engine and allow it to reach normal operating temperature.
  WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury.
2. Using the scan tool, read the active DTCs.
  Does the scan tool display P0463-FUEL LEVEL SENSOR 1 HIGH CIRCUIT?
  
  Yes
  - Go to step 2
  No
  - 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 .
(N4) FUEL LEVEL SIGNAL 1 CIRCUIT SHORTED TO VOLTAGE

Fig 1: Checking Fuel Level Signal 1 Circuit
Courtesy of CHRYSLER LLC
1. Turn the ignition off.
2. Disconnect the Fuel Pump Module harness connector.
3. Disconnect the Instrument Cluster (CCN) C2 harness connector.
4. Turn the ignition on.
5. Measure the voltage of the (N4) Fuel Level Signal 1 circuit in the Fuel Level Sensor harness connector.
  Is there any voltage present?
  
  Yes
  - Repair the short to voltage in the (N4) Fuel Level Signal 1 circuit.
  - Perform the BODY VERIFICATION TEST. Refer to DTC-Based Diagnostics/MODULE, Totally Integrated Power (TIPM) - Standard Procedure .
  No
  - Go to step 3
(N4) FUEL LEVEL SIGNAL 1 OPEN OR HIGH RESISTANCE

Fig 2: Checking Fuel Level Signal 1 Circuit
Courtesy of CHRYSLER LLC
1. Turn the ignition off.
2. Measure the resistance of the (N4) Fuel Level Signal 1 circuit between the Fuel Level Sensor harness connector and the Instrument Cluster (CCN) harness connector.
  Is the resistance below 5.0 Ohms?
  
  Yes
  - Go to step 4
  No
  - Repair the open circuit or high resistance in the (N4) Fuel Level Signal 1 circuit.
  - Perform the BODY VERIFICATION TEST. Refer to DTC-Based Diagnostics/MODULE, Totally Integrated Power (TIPM) - Standard Procedure .
(Z965/Z906) GROUND CIRCUIT OPEN OR HIGH RESISTANCE

Fig 3: Checking Ground Circuit
Courtesy of CHRYSLER LLC
1. Measure the resistance between ground and the (Z965/Z906) Ground circuit in the Fuel Level Sensor harness connector.
  Is the resistance below 5.0 Ohms?
  
  Yes
  - Go to step 5
  No
  - Repair the open or high resistance in the (Z965/Z906) Ground circuit.
  - Perform the BODY VERIFICATION TEST. Refer to DTC-Based Diagnostics/MODULE, Totally Integrated Power (TIPM) - Standard Procedure .
FUEL LEVEL SENSOR

Fig 4: Checking Fuel Level Signal Circuit
Courtesy of CHRYSLER LLC
1. Turn the ignition off.
2. Connect the Instrument Cluster (CCN) C2 harness connector.
3. Connect a jumper wire between ground and the (N4) Fuel Level Signal 1 circuit in the Fuel Level Sensor harness connector.
4. Turn the ignition on.
5. Using the scan tool, read the Fuel Level Sensor 1 signal voltage.
  Is the voltage below 1.0 Volt with the jumper wire in place?
  
  Yes
  - Replace the Fuel Level Sensor in accordance with the Service Information.
  - Perform the BODY VERIFICATION TEST. Refer to DTC-Based Diagnostics/MODULE, Totally Integrated Power (TIPM) - Standard Procedure .
  No
  - Go to step 6
INSTRUMENT CLUSTER (CCN)
1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Fuel Level Sensor 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
  - Repair as necessary.
  - Perform the BODY VERIFICATION TEST. Refer to DTC-Based Diagnostics/MODULE, Totally Integrated Power (TIPM) - Standard Procedure .
  No
  - Replace and program the Instrument Cluster (CCN) in accordance with the Service Information.
  - Perform the BODY VERIFICATION TEST. Refer to DTC-Based Diagnostics/MODULE, Totally Integrated Power (TIPM) - Standard Procedure .