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Home >> Dodge and Ram >> 2009 >> Journey R/T, AWD >> Repair and Diagnosis >> Engine Performance >> System >> DTCS P0441 To P0533 - GPEC >> P0461-Fuel Level Sensor 1 Performance >> Diagnostic Test

Diagnostic Test

  1. ACTIVE DTC 
    1. Turn the ignition on.
      NOTE: Diagnose and repair any Can bus or communication DTCs before proceeding with this test.
    2. With the scan tool, select View DTCs and review the DTC environmental information.

      Is the good trip counter greater than 0?

      Yes 

      No 

      • Go to step  2
  2. EXTERIOR FUEL TANK DAMAGE 
    1. 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 

      No 

      • Go to step  3
  3. FUEL PUMP MODULE WIRING AND CONNECTORS 
    1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Fuel Pump Module harness connector and the Totally Integrated Power Module (TIPM).
    2. Look for any chafed, pierced, pinched, or partially broken wires.
    3. Look for broken, bent, pushed out or corroded terminals.
    4. Refer to any Technical Service Bulletins that may apply.

      Were any problems found?

      Yes 

      No 

      • Go to step  4
  4. FUEL LEVEL SIGNAL 1 CIRCUIT VOLTAGE 
    Fig 1: Fuel Pump Module Harness Connector
    GC0129821Courtesy of CHRYSLER LLC
    1. Turn the ignition off.
    2. Disconnect the C1 Fuel Pump Module harness connector.
    3. Turn the ignition on.
    4. 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.
    5. Turn the ignition off.
    6. Connect a jumper wire between the (P37) Switch Return circuit and the (N4) Fuel Level Signal 1 circuit in the C1 Fuel Pump Module harness connector.
    7. Turn the ignition on.
    8. 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 

      • Go to step  5

      No 

      • Go to step  8
  5. (P37) SWITCH RETURN CIRCUIT OPEN OR HIGH RESISTANCE 
    Fig 2: Measuring Resistance Of Switch Return Circuit From Fuel Pump Module Harness Connector To C7 TIPM Harness Connector
    GC0129822Courtesy of CHRYSLER LLC
    1. Turn the ignition off.
    2. Disconnect the C7 Totally Integrated Power Module (TIPM) harness connector.
    3. Measure the resistance of the (P37) Switch Return circuit from the Fuel Pump Module harness connector to the C7 TIPM harness connector.

      Is the resistance below 5.0 ohms?

      Yes 

      • Go to step  6

      No 

  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 possible serious or fatal injury.
    1. Remove the fuel tank in accordance with the Service Information.
    2. Inspect the wiring and connectors between the C1 Fuel Pump Module harness connector and both Fuel Level Sensors.
    3. Look for any chafed, pierced, pinched, or partially broken wires.
    4. Verify that there is good pin to terminal contact at the Fuel Pump Module and the C7 TIPM harness connector.
    5. Look for broken, bent, pushed out or corroded terminals.

      Were any problems found?

      Yes 

      No 

      • Go to step  7
  7. FUEL LEVEL SENSOR 1 
    1. Remove Fuel Level Sensor 1.
    2. 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 

      No 

  8. (N4) FUEL LEVEL SIGNAL 1 CIRCUIT SHORTED TO VOLTAGE 
    Fig 3: Measuring Voltage Of Fuel Level Signal Circuit In Fuel Pump Module Harness Connector
    GC0129823Courtesy of CHRYSLER LLC
    1. Turn the ignition off.
    2. Disconnect the C7 Totally Integrated Power Module (TIPM) harness connector.
    3. Turn the ignition on.
    4. Measure the voltage of the (N4) Fuel Level Signal 1 circuit in the C1 Fuel Pump Module harness connector.

      Is there any voltage present?

      Yes 

      No 

      • Go to step  9
  9. (N4) FUEL LEVEL SIGNAL 1 CIRCUIT SHORTED TO GROUND 
    Fig 4: Measuring Resistance Between Ground And Fuel Level Signal Circuit In Fuel Pump Module Harness Connector
    GC0129824Courtesy of CHRYSLER LLC
    1. Turn the ignition off.
    2. Measure the resistance between ground and the (N4) Fuel Level Signal 1 circuit in the C1 Fuel Pump Module harness connector.

      Is the resistance above 100 ohms?

      Yes 

      • Go to step  10

      No 

  10. EXCESSIVE RESISTANCE IN THE (N4) FUEL LEVEL SIGNAL 1 CIRCUIT 
    Fig 5: Measuring Resistance Of Fuel Level Signal Circuit From Fuel Pump Module Harness Connector To TIPM Harness Connector
    GC0129825Courtesy of CHRYSLER LLC
    1. Measure the resistance of the (N4) Fuel Level Signal 1 circuit from the C1 Fuel Pump Module harness connector to the C7 TIPM harness connector.

      Is the resistance below 5.0 ohms?

      Yes 

      • Go to step  11

      No 

  11. TOTALLY INTEGRATED POWER MODULE (TIPM) 
    1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Fuel Pump Module and the Totally Integrated Power Module (TIPM).
    2. Look for any chafed, pierced, pinched, or partially broken wires.
    3. Look for broken, bent, pushed out or corroded terminals. Verify that there is good pin to terminal contact in the C1 Fuel Pump Module and the TIPM connectors.
    4. Refer to any Technical Service Bulletins that may apply.

      Were any problems found?

      Yes 

      No 

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