Dodge Neon / Neon SRT-4. Manual — part 481
Symptom:
FUEL LEVEL SENSOR OPEN
When Monitored and Set Condition:
FUEL LEVEL SENSOR OPEN
When Monitored:
With the ignition on. (Customer Complaint: fuel gauge displays empty)
Set Condition:
The Instrument Cluster monitors the Fuel Level Sensor Signal circuit
resistance. If the Cluster detects a resistance greater than 1500 ohms or less than 25 ohms
for 18 seconds, this code will set.
POSSIBLE CAUSES
INTERMITTENT CONDITION
FUEL LEVEL SENSOR SIGNAL CIRCUIT SHORT TO VOLTAGE
FUEL LEVEL SENSOR SIGNAL CIRCUIT OPEN
FUEL PUMP MODULE GROUND CIRCUIT OPEN
FUEL LEVEL SENSOR
INSTRUMENT CLUSTER
TEST
ACTION
APPLICABILITY
1
Turn the ignition on.
With the DRBIII
t, erase DTC’s.
Cycle the ignition off and then back on.
With the DRBIII
t, read DTC’s.
Does the DRBIII
t display 9Fuel Level Sensor Open9?
All
No
→ Test complete. DTC is intermittent. Road test the vehicle and
recheck for DTC’s. If the code returns, rerun this test. Refer to any
Technical Service Bulletins (TSB) that may aply. Inspect related
harness and connectors.
Perform BODY VERIFICATION TEST - VER 1.
Yes
→ Go To 2
2
Turn the ignition off.
Disconnect the Fuel Pump Module harness connector.
Disconnect the Instrument Cluster harness connector.
Check connectors - Clean/repair as necessary.
Turn the ignition on.
NOTE: The ignition must be turned off for at least 10 minutes to allow the
cluster to go to
(sleep( before proceeding with this test.
Measure the voltage between the Fuel Level Sensor Signal circuit and ground.
Is there any voltage present?
All
Yes
→ Repair the Fuel Level Sensor Signal circuit for a short to voltage.
Perform BODY VERIFICATION TEST - VER 1.
No
→ Go To 3
146
INSTRUMENT CLUSTER
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Disconnect the Fuel Pump Module harness connector.
Check connectors - Clean/repair as necessary.
Connect a jumper wire between the Fuel Level Sensor Signal circuit and ground.
Turn the ignition on.
With the DRBIII
t in Sensors, read the Fuel Sender Volts.
Does the DRBIII
t display 0 (zero) volts?
All
Yes
→ Go To 4
No
→ Repair the Fuel Level Sensor Signal circuit for an open.
Perform BODY VERIFICATION TEST - VER 1.
4
Turn the ignition off.
Disconnect the Fuel Pump Module harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance between ground and the Fuel Level Sensor Ground circuit.
Is the resistance below 5.0 ohms?
All
Yes
→ Go To 5
No
→ Repair the Fuel Pump Module Ground circuit for an open.
Perform BODY VERIFICATION TEST - VER 1.
5
Turn the ignition off.
Disconnect the Fuel Pump Module harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance of the Fuel Level Sensor between the Sensor Signal circuit
pin and the Sensor Ground circuit pin.
Is the resistance above 1500 ohms?
All
Yes
→ Replace the Fuel Level Sender in accordance with the Service
Information.
Perform BODY VERIFICATION TEST - VER 1.
No
→ Replace the Instrument Cluster in accordance with the Service
Information.
Perform BODY VERIFICATION TEST - VER 1.
147
INSTRUMENT CLUSTER
FUEL LEVEL SENSOR OPEN —
Continued
Symptom:
FUEL LEVEL SENSOR SHORT
When Monitored and Set Condition:
FUEL LEVEL SENSOR SHORT
When Monitored:
When the ignition is on. (Customer Complaint: fuel gauge displays
empty).
Set Condition:
The Instrument Cluster monitors the fuel level sensor signal circuit for a
resistance value between approximately 25 ohms to 1100 ohms. If the Cluster senses a
resistance less than 25 ohms, this code will set.
POSSIBLE CAUSES
FUEL LEVEL SENSOR SHORT INTERMITTENT CONDITION
FUEL LEVEL SENSOR
FUEL LEVEL SENSOR SIGNAL CIRCUIT SHORT TO SENSOR GROUND CIRCUIT
INSTRUMENT CLUSTER
TEST
ACTION
APPLICABILITY
1
With the DRBIII
t, erase DTC’s.
Turn the ignition on, wait for one minute.
With the DRBIII
t, read DTC’s.
Does the DRBIII
t display Fuel Level Sensor Short?
All
No
→ Test complete. DTC is intermittent. Road test the vehicle and
recheck for DTC’s. If the code returns, rerun this test. Refer to any
Technical Service Bulletins (TSB) that may apply. Inspect related
harness and connectors.
Perform BODY VERIFICATION TEST - VER 1.
Yes
→ Go To 2
2
Turn the ignition off.
Disconnect the Fuel Pump Module harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance of the Fuel Level Sensor between the Sensor Signal circuit
pin and the Sensor Ground circuit pin (sensor side).
Is the resistance below 50.0 ohms?
All
Yes
→ Replace the Fuel Level Sensor in accordance with the Service
Information.
Perform BODY VERIFICATION TEST - VER 1.
No
→ Go To 3
148
INSTRUMENT CLUSTER
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
Disconnect the Instrument Cluster harness connector.
Disconnect the Fuel Pump Module harness connector.
Check connectors - Clean/repair as necessary.
Measure the resistance of the Fuel Level Sensor Signal circuit to ground.
Is the resistance below 10,000 (10 K) ohms? NOTE: it should be infinite.
All
Yes
→ Repair the Fuel Level Sensor Signal circuit for a short to the
Sensor Ground circuit.
Perform BODY VERIFICATION TEST - VER 1.
No
→ Test Complete.
149
INSTRUMENT CLUSTER
FUEL LEVEL SENSOR SHORT —
Continued
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