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<servinfo
releasenbr="1"
update="original"
id="lf1fb9d139d54f40852e535b32437402"
><title
>P0461-FUEL LEVEL SENSOR 1 PERFORMANCE</title><figure
figtype="2-column-portrait-no-fig-id"
id="j3fe27ff88604e6e97e1866a55e5822e"
><graphic
graphicname="7a033925"
></graphic></figure><para
><ptxt
>For a complete wiring diagram <emph
>Refer to Section 8W</emph>.</ptxt></para><diagnostic
type="condition"
><title
>Theory of Operation</title><condition
><para
><ptxt
>The fuel level rationality will set a fault for a fuel level reading that does not change over an accumulated mileage threshold to keep stuck high or stuck low fuel levels from disabling OBD
monitors. If the vehicle is fitted with a saddle tank fuel system this feature includes diagnostics for both of the sending units and diagnostics for a siphon tube that has become disconnected or plugged.
The power up test looks to see a large enough fuel level voltage change from the last key-off to the following engine run. The engine run test looks to see a fuel level voltage change over an accumulated
mileage. </ptxt></para><spec
><list1
><item
><ptxt
><emph
>When Monitored:</emph></ptxt><para
><ptxt
>TEST No.1: With the ignition on, the fuel level is compared to the previous key down after a 20 second delay. TEST No.2: The PCM monitors the fuel level at ignition on.</ptxt></para></item><item
><ptxt
><emph
>Set Condition:</emph></ptxt><para
><ptxt
>TEST No.1: If the PCM does not see a difference in fuel level of greater than 0.1 volt the test will fail. TEST No.2: If the PCM does not see a change in the fuel level of .1765 over a set amount
of miles the test will fail. Two trip fault. Three good trips to turn off the MIL.</ptxt></para></item></list1><table
><tgroup
xmlns:fo="http://www.w3.org/1999/XSL/Format"
xmlns:saxon="http://icl.com/saxon"
border-width.conditionality="retain"
font-size="7pt"
width="100%"
border-collapse="collapse-with-precedence"
table-omit-header-at-break="false"
border-width="1pt"
border-color="black"
border-style="solid"
space-after="6pt"
table-layout="fixed"
><table-column
column-number="1"
column-width="proportional-column-width(396)"
></table-column><thead
><row
><entry
valign="bottom"
align="center"
><ptxt
><emph
>Possible Causes</emph></ptxt></entry></row></thead><tbody
><row
><entry
valign="top"
align="left"
><ptxt
>(N4) FUEL LEVEL SIGNAL CIRCUIT OPEN</ptxt></entry></row><row
><entry
valign="top"
align="left"
><ptxt
>(N4) FUEL LEVEL SIGNAL CIRCUIT SHORTED TO GROUND</ptxt></entry></row><row
><entry
valign="top"
align="left"
><ptxt
>(K900) SENSOR GROUND CIRCUIT OPEN</ptxt></entry></row><row
><entry
valign="top"
align="left"
><ptxt
>FUEL TANK</ptxt></entry></row><row
><entry
valign="top"
align="left"
><ptxt
>FUEL LEVEL SENSOR</ptxt></entry></row></tbody></tgroup></table></spec><para
><ptxt
><emph
>Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. <extxref
document="SOFTLINK"
extrefid="0900000030"
> (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)</extxref>.</emph></ptxt></para></condition></diagnostic><diagnostic
type="test"
><?STEP 1------------------------------------------------------------------------------------------------------------------------------------------------------------------------------?><testgrp
><title
>Diagnostic Test</title><spec
><ptxt
><testno><emph>1.</emph></testno> <emph
>ACTIVE DTC</emph></ptxt></spec><attention3
name="NOTE"
><ptxt
>Diagnose any CAN - C or CAN - B Communication DTCs before continuing.</ptxt></attention3><attention3
name="NOTE"
><ptxt
>Diagnose P0462 or P0463 first, if set along with P0461.</ptxt></attention3><test1
><ptxt
>Start the engine.</ptxt></test1><test1
><ptxt
>Allow the engine to reach normal operating temperature.</ptxt></test1><test1
><ptxt
>With a scan tool, select View DTCs and record the related Freeze Frame data.</ptxt></test1><test1
><attention3
name="NOTE"
><ptxt
>It may be necessary to drive the vehicle to meet the conditions to set this DTC, try to repeat the conditions in which the fault originally set by reviewing the Freeze
Frame data.</ptxt></attention3></test1><question
>Is the DTC Active or Pending at this time?</question><result
>Yes</result><action
><list1
><item
><ptxt
>Go To <intxref
refid="o599a5356e714352862f74aef6d4df25"
>2</intxref></ptxt></item></list1></action><result
>No</result><action
><list1
><item
><ptxt
>Refer to the INTERMITTENT CONDITION Diagnostic Procedure.</ptxt></item><item
><ptxt
>Perform the POWERTRAIN VERIFICATION TEST. <extxref
document="SOFTLINK"
extrefid="0900000360"
>(Refer to 9 - ENGINE - STANDARD PROCEDURE)</extxref> <symbol
name="SKIP"
></symbol></ptxt></item></list1></action></testgrp><?STEP 2------------------------------------------------------------------------------------------------------------------------------------------------------------------------------?><testgrp
id="o599a5356e714352862f74aef6d4df25"
><spec
><ptxt
><testno><emph>2.</emph></testno> <emph
>VISUALLY INSPECT FUEL TANK</emph></ptxt></spec><test1
><ptxt
>Visually inspect the Fuel Tank for damage that may restrict the Fuel Sending Unit float from moving.</ptxt></test1><question
>Is the Fuel Tank OK?</question><result
>Yes</result><action
><list1
><item
><ptxt
>Go To <intxref
refid="p9d41d33c6d7402ca9e54f526cc8af46"
>3</intxref></ptxt></item></list1></action><result
>No</result><action
><list1
><item
><ptxt
>Replace the Fuel Tank as necessary.</ptxt></item><item
><ptxt
>Perform the POWERTRAIN VERIFICATION TEST. <extxref
document="SOFTLINK"
extrefid="0900000360"
>(Refer to 9 - ENGINE - STANDARD PROCEDURE)</extxref> <symbol
name="SKIP"
></symbol></ptxt></item></list1></action></testgrp><?STEP 3------------------------------------------------------------------------------------------------------------------------------------------------------------------------------?><testgrp
id="p9d41d33c6d7402ca9e54f526cc8af46"
><spec
><ptxt
><testno><emph>3.</emph></testno> <emph
>(N4) FUEL LEVEL SIGNAL CIRCUIT OPEN</emph></ptxt></spec><figure
figtype="1-column-portrait-no-fig-id"
id="id37dc4cf40f42a8b8384283b9a338f4"
><graphic
graphicname="7a033926"
></graphic></figure><test1
><ptxt
>Turn the ignition off.</ptxt></test1><test1
><ptxt
>Disconnect the Fuel Pump Module harness connector.</ptxt></test1><test1
><ptxt
>Disconnect the C7 TIPM harness connector.</ptxt></test1><test1
><ptxt
>Measure the resistance of the (N4) Fuel Level Signal circuit from the Fuel Pump Module harness connector to the TIPM harness connector.</ptxt></test1><question
>Is the resistance below 5.0 ohms?</question><result
>Yes</result><action
><list1
><item
><ptxt
>Go To <intxref
refid="n72a8447a15943878fb3018554151ade"
>4</intxref></ptxt></item></list1></action><result
>No</result><action
><list1
><item
><ptxt
>Repair the open in the (N4) Fuel Level Signal circuit.</ptxt></item><item
><ptxt
>Perform BODY VERIFICATION TEST-VER 1. <extxref
document="SOFTLINK"
extrefid="0857000360"
>(Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL MODULES - STANDARD PROCEDURE)</extxref><symbol
name="SKIP"
></symbol></ptxt></item></list1></action></testgrp><?STEP 4-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------?><testgrp
id="n72a8447a15943878fb3018554151ade"
><spec
><ptxt
><testno><emph>4.</emph></testno> <emph
>(N4) FUEL LEVEL SIGNAL CIRCUIT SHORTED TO GROUND</emph></ptxt></spec><figure
figtype="1-column-portrait-no-fig-id"
id="pcac723fc85e4b5583cbb72d113f000b"
><graphic
graphicname="7a033927"
></graphic></figure><test1
><ptxt
>Measure the resistance between ground and the (N4) Fuel Level Signal circuit in the Fuel Pump Module harness connector.</ptxt></test1><question
>Is the resistance below 100 ohms?</question><result
>Yes</result><action
><list1
><item
><ptxt
>Repair the short to ground in the (N4) Fuel Level Signal circuit.</ptxt></item><item
><ptxt
>Perform the POWERTRAIN VERIFICATION TEST. <extxref
document="SOFTLINK"
extrefid="0900000360"
>(Refer to 9 - ENGINE - STANDARD PROCEDURE)</extxref> </ptxt></item></list1></action><result
>No</result><action
><list1
><item
><ptxt
>Go To <intxref
refid="j57c6f8c730e4136b36f38752b210cdc"
>5</intxref><symbol
name="SKIP"
></symbol></ptxt></item></list1></action></testgrp><?STEP 5-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------?><testgrp
id="j57c6f8c730e4136b36f38752b210cdc"
><spec
><ptxt
><testno><emph>5.</emph></testno> <emph
>(K900) SENSOR GROUND CIRCUIT OPEN</emph></ptxt></spec><figure
figtype="1-column-portrait-no-fig-id"
id="f4244d511d5c410f9a4df741ac6fd533"
><graphic
graphicname="7a033928"
></graphic></figure><test1
><ptxt
>Disconnect the C2 PCM harness connector.</ptxt></test1><test1
><attention2
name="CAUTION"
><ptxt
>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.</ptxt></attention2></test1><test1
><ptxt
>Measure the resistance of the (K900) Sensor Ground circuit from the Fuel Pump Module harness connector to the appropriate terminal of special tool #8815.</ptxt></test1><question
>Is the resistance below 100 ohms?</question><result
>Yes</result><action
><list1
><item
><ptxt
>Repair the open in the (K900) Sensor Ground circuit.</ptxt></item><item
><ptxt
>Perform the POWERTRAIN VERIFICATION TEST. <extxref
document="SOFTLINK"
extrefid="0900000360"
>(Refer to 9 - ENGINE - STANDARD PROCEDURE)</extxref> </ptxt></item></list1></action><result
>No</result><action
><list1
><item
><ptxt
>Go To <intxref
refid="c0188021873443ebbcd5cfc3755ca40e"
>6</intxref><symbol
name="SKIP"
></symbol></ptxt></item></list1></action></testgrp><?STEP 7-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------?><testgrp
id="c0188021873443ebbcd5cfc3755ca40e"
><spec
><ptxt
><testno><emph>6.</emph></testno> <emph
>INTERNAL INSPECTION OF THE FUEL TANK</emph></ptxt></spec><attention1
name="WARNING"
><ptxt
>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.</ptxt></attention1><test1
><ptxt
>Remove the Fuel Tank per Service Information.</ptxt></test1><test1
><ptxt
>Remove the Fuel Pump Module.</ptxt></test1><test1
><ptxt
>Visually inspect the inside of the Fuel Tank for any obstructions or deformities.</ptxt></test1><test1
><ptxt
>Inspect the Fuel Pump Module Float arm for damage.</ptxt></test1><question
>Were any problems found?</question><result
>Yes</result><action
><list1
><item
><ptxt
>Repair or replace as necessary.</ptxt></item><item
><ptxt
>Perform the POWERTRAIN VERIFICATION TEST. <extxref
document="SOFTLINK"
extrefid="0900000360"
>(Refer to 9 - ENGINE - STANDARD PROCEDURE)</extxref> </ptxt></item></list1></action><result
>No</result><action
><list1
><item
><ptxt
>Go To <intxref
refid="cbf0edb600414bd0874e4dfde7c20e16"
>7</intxref> <symbol
name="skip"
></symbol></ptxt></item></list1></action></testgrp><?STEP 8-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------?><testgrp
id="cbf0edb600414bd0874e4dfde7c20e16"
><spec
><ptxt
><testno><emph>7.</emph></testno> <emph
>FUEL LEVEL SENSOR</emph></ptxt></spec><question
>If there are no possible causes remaining, view repair.</question><result
>Repair</result><action
><list1
><item
><ptxt
>Replace the Fuel Level Sensor.</ptxt></item><item
><ptxt
>Perform the POWERTRAIN VERIFICATION TEST. <extxref
document="SOFTLINK"
extrefid="0900000360"
>(Refer to 9 - ENGINE - STANDARD PROCEDURE)</extxref> <symbol
name="SKIP"
></symbol></ptxt></item></list1></action></testgrp></diagnostic></servinfo>