Diagnostic Test

WARNING: This page is about a different car, the 2015 Fiat 500. However, it is still accessible from the selected car via links, so may be relevant.

FUEL LEVEL SENSOR CIRCUIT DTCS SET IN THE BCM
NOTE:
If the P0462 or P0463 are also set, diagnose and repair those DTCs before continuing with this test procedure.

Are any Fuel Level Sensor Circuit DTCs set in the BCM?

Yes
- Diagnose the appropriate Fuel Level Sensor Circuit DTC in the BCM. Refer to BODY CONTROL MODULE (BCM) - DIAGNOSTIC CODE INDEX - 500 - EXCEPT ELECTRIC .
No
- Go To 2
VISUALLY INSPECT FUEL TANK
1. Visually inspect the Fuel Tank for damage that may restrict the Fuel Sending Unit float from moving.
  Is the Fuel Tank damaged?
  
  Yes
  - Replace the Fuel Tank in accordance with the service information. Refer to TANK, FUEL . .
  - Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST, 16V Turbo .
  No
  - Go To 3
INTERNAL INSPECTION OF THE FUEL TANK
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. Refer to TANK, FUEL .
2. Remove the Fuel Pump Module. Refer to MODULE, FUEL PUMP .
3. Visually inspect the inside of the Fuel Tank for any obstructions or deformities.
4. Inspect the Fuel Pump Module Float arm for damage that may restrict movement.
  Were any problems found?
  
  Yes
  - Repair or replace as necessary.
  - Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST, 16V Turbo .
  No
  - Go To 4
CHECK RELATED PCM AND COMPONENT CONNECTIONS
1. Perform any Service Bulletins that apply.
2. Disconnect all PCM harness connectors.
3. Disconnect all related in-line harness connections (if equipped).
4. Disconnect the related component harness connectors.
5. Inspect harness connectors, component connectors, and all male and female terminals for the following conditions:
  - Proper connector installation.
  - Damaged connector locks.
  - Corrosion.
  - Other signs of water intrusion.
  - Weather seal damage (if equipped).
  - Bent terminals.
  - Overheating due to a poor connection (terminal may be discolored due to excessive current draw).
  - Terminals that have been pushed back into the connector cavity.
  - Check for spread terminals and verify proper terminal tension.
  Repair any conditions that are found.
6. Reconnect all PCM harness connectors. Be certain that all harness connectors are fully seated and the connector locks are fully engaged.
7. Reconnect all in-line harness connectors (if equipped). Be certain that all connectors are fully seated and the connector locks are fully engaged.
8. Reconnect all related component harness connectors. Be certain that all connectors are fully seated and the connector locks are fully engaged.
9. With the scan tool, erase DTCs.
10. Test drive or operate the vehicle in accordance with the when monitored and set conditions.
11. With the scan tool, read DTCs.
  Did the DTC return?
  
  Yes
  - Replace the Powertrain Control Module in accordance with the Service information. Refer to MODULE, POWERTRAIN CONTROL, REMOVAL .
  - Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST, 16V Turbo .
  No
  - Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST, 16V Turbo .
  - Test complete.