Diagnostic Procedure

WARNING: This page is about a different car, the 2004 Dodge Pickup and 2004 Dodge Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Refer to VERIFICATION TESTS for appropriate verification test procedures.

Ignition on, engine not running.
With the DRBIII®, read DTCs and record the related Freeze Frame data.

Check for any related TSBs.

With the DRBIII®, read the Fuel Level Sensor voltage.

Is the Fuel Level Sensor voltage above 4.9 volts?
1. Yes --> Go To 2
2. No --> Refer to the SYMPTOM: INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
  Perform POWERTRAIN VERIFICATION TEST VER - 2 .
Turn the ignition off.
Disconnect the Fuel Pump Module electrical harness connector.

Ignition on, engine not running.

Connect a jumper wire between the (G8) Fuel Level Sensor Signal circuit and the (K4) Sensor ground circuit at the Fuel Pump Module harness connector.

With the DRBIII®, read the Fuel Level Sensor voltage.

Did the Fuel Level Sensor voltage change from above 4.8 volts to below 0.4 of a volt?
1. Yes --> Replace the Fuel Level Sensor.
  Perform POWERTRAIN VERIFICATION TEST VER - 2 .
2. No --> Go To 3
NOTE: Remove the jumper wire before continuing.
Turn the ignition off.
Disconnect the PCM harness connectors.

Ignition on, engine not running.

Measure the voltage on the (G8) Fuel Level Sensor Signal circuit in the Fuel Pump harness connector.

Is the voltage above 10.0 volts?
1. Yes --> Repair the short to voltage in the (G8) Fuel Level Sensor Signal circuit.
  Perform POWERTRAIN VERIFICATION TEST VER - 2 .
2. No --> Go To 4
Turn the ignition off.
Measure the resistance of the (G8) Fuel Level Sensor Signal circuit from the PCM harness connector to the Fuel Pump Module harness connector.

Is the resistance below 5.0 ohms?
1. Yes --> Go To 5
2. No --> Repair the open in the (G8) Fuel Level Sensor Signal circuit.
  Perform POWERTRAIN VERIFICATION TEST VER - 2 .
Measure the resistance of the (K4) Sensor ground circuit from the PCM harness connector to the Fuel Pump Module harness connector.
Is the resistance below 5.0 ohms?
1. Yes --> Go To 6
2. No --> Repair the open in the (K4) Sensor ground circuit.
  Perform POWERTRAIN VERIFICATION TEST VER - 2 .

NOTE: Before continuing, check the PCM harness connector terminals for corrosion, damage, or terminal push out. Repair as necessary.

Using the schematics as a guide, inspect the wire harness and connectors. Pay particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
1. Repair
  1. Replace and program the Powertrain Control Module per Service Information.
  2. Perform POWERTRAIN VERIFICATION TEST VER - 2 .