Diagnostic Test

1) DTC IS ACTIVE
Turn the ignition on.

With the scan tool, select View DTCs and review the DTC environmental information.

Is the good trip counter greater than 0?

Yes
1. The DTC is not active at this time. Refer to *CHECKING FOR AN INTERMITTENT CONDITION diagnostic procedure.
No
1. Go to step 2).
2) EXTERIOR FUEL TANK DAMAGE
Inspect the exterior of the fuel tank for any damage that may restrict the movement of the fuel level sensor floats.

Were any problems found?

Yes
1. Replace the fuel tank as necessary.
2. Perform BODY VERIFICATION TEST - VER 1 .
No
1. Go to step 3).
3) FUEL PUMP MODULE WIRING AND CONNECTORS
Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Fuel Pump Module harness connector and the Instrument Cluster (CCN).

Look for any chafed, pierced, pinched, or partially broken wires.

Look for broken, bent, pushed out or corroded terminals.

Refer to any Technical Service Bulletins that may apply.

Were any problems found?

Yes
1. Repair as necessary.
2. Perform BODY VERIFICATION TEST - VER 1 .
No
1. Go to step 4).
4) FUEL LEVEL SIGNAL 1 CIRCUIT VOLTAGE

Fig 1: Fuel Pump Module Harness Connector
Courtesy of CHRYSLER LLC

Turn the ignition off.

Disconnect the Fuel Pump Module harness connector.

Turn the ignition on.

With the scan tool, read the Fuel Level Sensor 1 circuit voltage.

NOTE: The sensor voltage should be approximately 5.0 volts (plus or minus.1 volt) with connector disconnected.

Turn the ignition off.

Connect a jumper wire between ground and the (N4) Fuel Level Signal 1 circuit in the Fuel Pump Module harness connector.

Turn the ignition on.

With the scan tool, read the Fuel Level Sensor 1 circuit voltage.

NOTE: The sensor voltage should be approximately 0.0 volts (plus or minus.1 volt) with the jumper wire in place.

Does the scan tool display the voltage as described above?

Yes
1. Go to step 5).
No
1. Go to step 8).
5) (Z916) GROUND CIRCUIT OPEN OR HIGH RESISTANCE

Fig 2: Measuring Resistance Between Ground And (Z965) Ground Circuit In Fuel Pump Module Harness Connector
Courtesy of CHRYSLER LLC

Turn the ignition off.

Measure the resistance between ground and the (Z916) Ground circuit in the Fuel Pump Module harness connector.

Is the resistance below 5.0 ohms?

Yes
1. Go to step 6).
No
1. Repair the (Z916) Ground for an open circuit or high resistance.
2. Perform BODY VERIFICATION TEST - VER 1 .
6) FUEL TANK WIRING HARNESS INSPECTION
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 personal injury or death.

Remove the fuel tank in accordance with the Service Information.

Inspect the wiring and connectors between the Fuel Pump Module harness connector and both Fuel Level Sensors.

Look for any chafed, pierced, pinched, or partially broken wires.

Look for broken, bent, pushed out or corroded terminals.

Were any problems found?

Yes
1. Repair as necessary.
2. Perform BODY VERIFICATION TEST - VER 1 .
No
1. Go to step 7).
7) FUEL LEVEL SENSOR 1
Remove Fuel Level Sensor 1.

Inspect Fuel Level Sensor 1 and the inside of the fuel tank for any condition that would restrict the movement of the fuel level sensor float.

Were any problems found?

Yes
1. Repair or replace the fuel tank components as necessary.
2. Perform BODY VERIFICATION TEST - VER 1 .
No
1. Replace the Fuel Level Sensor 1.
2. Perform BODY VERIFICATION TEST - VER 1 .
8) (N4) FUEL LEVEL SIGNAL 1 CIRCUIT SHORTED TO VOLTAGE

Fig 3: Measuring Voltage Of (N4) Fuel Level Signal 1 Circuit In Fuel Level Sensor 1 Harness Connector
Courtesy of CHRYSLER LLC

Turn the ignition off.

Disconnect the Instrument Cluster (CCN) connector.

Turn the ignition on.

Measure the voltage of the (N4) Fuel Level Signal 1 circuit in the Fuel Level Sensor 1 harness connector.

Is there any voltage present?

Yes
1. Repair the (N4) Fuel Level Signal 1 circuit for a short to voltage.
2. Perform BODY VERIFICATION TEST - VER 1 .
No
1. Go to step 9).
9) (N4) FUEL LEVEL SIGNAL 1 CIRCUIT SHORTED TO GROUND

Fig 4: Measuring Resistance Between Ground And (N4) Fuel Level Signal 1 Circuit In Fuel Level Sensor 1 Harness Connector
Courtesy of CHRYSLER LLC

Turn the ignition off.

Measure the resistance between ground and the (N4) Fuel Level Signal 1 circuit in the Fuel Level Sensor 1 harness connector.

Is the resistance above 100 ohms?

Yes
1. Go to step 10).
No
1. Repair the (N4) Fuel Level Signal 1 circuit for a short to ground.
2. Perform BODY VERIFICATION TEST - VER 1 .
10) (N4) FUEL LEVEL SIGNAL 1 CIRCUIT OPEN OR HIGH RESISTANCE

Fig 5: Checking Fuel Level Signal 1 Circuit For Open Or High Resistance
Courtesy of CHRYSLER LLC

Measure the resistance of the (N4) Fuel Level Signal 1 circuit between the Fuel Level Sensor 1 harness connector and the Instrument Cluster (CCN) harness connector.

Is the resistance below 5.0 ohms?

Yes
1. Go to step 11).
No
1. Repair the (N4) Fuel Level Signal 1 circuit for an open circuit or high resistance.
2. Perform BODY VERIFICATION TEST - VER 1 .
11) INSTRUMENT CLUSTER (CCN)
Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Fuel Pump Module and the Instrument Cluster (CCN).

Look for any chafed, pierced, pinched, or partially broken wires.

Look for broken, bent, pushed out or corroded terminals.

Refer to any Technical Service Bulletins that may apply.

Were any problems found?

Yes
1. Repair as necessary.
2. Perform BODY VERIFICATION TEST - VER 1 .
No
1. Replace the Instrument Cluster (CCN) in accordance with the Service Information.
2. Perform BODY VERIFICATION TEST - VER 1 .