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.

NOTE: Diagnose P0462 or P0463 first, if set along with P0461.

NOTE: Inspect the Fuel Pump Module harness connector for any corrosion or damage.

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

Is the Good Trip Counter displayed and equal to zero?
1. Yes --> Go To 2
2. No --> Refer to the SYMPTOM: INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
Visually inspect the Fuel Tank for damage that may restrict the Fuel Sending Unit float from moving.
Is the Fuel Tank OK?
1. Yes --> Go To 3
2. No --> Replace the Fuel Tank as necessary.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
Turn the ignition off.
Disconnect the Fuel Pump Module harness connector.

Disconnect the PCM harness connectors.

CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING THE PCM HARNESS CONNECTORS WELL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.

Measure the resistance of the (N4) Fuel Level Signal circuit from the Fuel Pump Module harness connector to the appropriate terminal of special tool #8815.

Is the resistance below 5.0 ohms?
1. Yes --> Go To 4
2. No --> Repair the open in the (N4) Fuel Level Signal circuit.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
Measure the resistance between ground and the (N4) Fuel Level Signal circuit at the Fuel Pump Module harness connector.
Is the resistance below 100 ohms?
1. Yes --> Repair the short to ground in the (N4) Fuel Level Signal circuit.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
2. No --> Go To 5

CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.

Measure the resistance of the (K900) Sensor ground circuit from the Fuel Pump Module harness connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
1. Yes --> Go To 6
2. No --> Repair the open in the (K900) Sensor ground circuit.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .

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 per 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 problems found?
1. Yes --> Repair or replace as necessary.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
2. No --> Go To 7
If there are no possible causes remaining, view repair.
1. Repair
  1. Replace the Fuel Level Sensor.
  2. Perform POWERTRAIN VERIFICATION TEST VER - 5 .