Test TC-150A: Fuel Level Sending Unit Volts Too High

NOTE: For connector terminal identification, see CONNECTOR IDENTIFICATION . For component location and wiring diagram, see WIRING DIAGRAMS article.

Using scan tool, read fuel level sending unit voltage. If voltage is more than 4.37 volts on AB and BE/BR bodies, or more than 4.70 volts on all other bodies, go to step 5) . If voltage is not as specified, go to next step.
Wiggle connectors and harness at fuel pump module while observing scan tool display. If voltage changes while wiggling connectors and harness, repair connector or harness that caused voltage change and perform TEST VER-2A: ROAD TEST VERIFICATION . If voltage does not change, go to next step.
Condition required to set DTC is not present at this time. FUEL LEVEL SENDING UNIT VOLTAGE TOO HIGH DTC sets if Powertrain Control Module (PCM) senses more than 4.37 volts on AB and BE/BR bodies, or more than 4.7 volts on all other bodies for 2 seconds while ignition is on on BE/BR bodies, or ignition is on and battery voltage is more than 10.4 volts on all other bodies. Possible causes are: open fuel level sensor signal, defective fuel level sending unit, defective PCM, defective connector terminals or connector wires. Go to next step.
Inspect all related wiring and connectors. Repair wiring and connectors as necessary and perform TEST VER-2A: ROAD TEST VERIFICATION . If wiring and connectors are okay, test is complete. Perform TEST VER-2A: ROAD TEST VERIFICATION .
Disconnect fuel pump module connector. Inspect connector and terminals for damage. Repair connector and terminals as necessary. If connector and terminals are okay, go to next step.
On TJ and ZJ bodies, go to next step. On all other bodies, use scan tool to check voltage on fuel level sensor signal circuit (Light Blue/Black wire on AB body; Dark Blue wire on AN and DN bodies; Dark Blue/White wire on BE/BR bodies). If voltage is more than 6 volts, repair signal circuit for short to voltage and perform TEST VER-2A: ROAD TEST VERIFICATION . If voltage is 6 volts or less, go to next step.
Connect a jumper wire between fuel pump connector, fuel level sensor signal circuit (Light Blue/Black wire on AB and ZJ bodies; Dark Blue wire on AN and DN bodies; Dark Blue/White wire on BE/BR bodies; Dark Blue/Light Green wire on TJ and XJ bodies) and sensor ground circuit (Brown/Yellow wire on TJ, XJ and ZJ bodies; Black/Light Blue wire on all other bodies). Go to next step.
Using scan tool, read fuel level sending unit voltage. If voltage is less than one volt on AB body, perform TEST TC-150B: FUEL LEVEL SENDING UNIT VOLTS TOO LOW . On all other bodies, replace fuel pump module and perform TEST VER-2A: ROAD TEST VERIFICATION . If voltage is one volt or more, go to next step.
Move jumper wire from fuel pump connector, sensor ground circuit (Brown/Yellow wire on TJ, XJ and ZJ bodies; Black/Light Blue wire on all other bodies) to ground. If voltage is less than one volt, repair open sensor ground circuit and perform TEST VER-2A: ROAD TEST VERIFICATION . if voltage is one volt or more go to next step.
Turn ignition off. Disconnect Powertrain Control Module (PCM) connectors. Inspect connectors and terminals for damage. Repair connectors and terminals as necessary and perform TEST VER-2A: ROAD TEST VERIFICATION . If connectors and terminals are okay, go to next step.
Using an external ohmmeter, check resistance of fuel level sensor signal circuit (Light Blue/Black wire on AB and ZJ bodies; Dark Blue wire on AN and DN bodies; Dark Blue/White wire on BE/BR bodies; Dark Blue/Light Green wire on TJ and XJ bodies) between PCM Gray connector and fuel pump module connector. If resistance is less than 5 ohms, replace PCM and perform TEST VER-2A: ROAD TEST VERIFICATION . If resistance is 5 ohms or more, repair open fuel level sensor signal circuit and perform TEST VER-2A: ROAD TEST VERIFICATION