Circuit Description
The right Fuel Level sensor, mounted in the rear side of the right fuel tank, measures fuel level changes within the right fuel tank. The Fuel Level sensor 2 has a 5.0 volt reference circuit, a ground, and a signal circuit.
When the fuel level is high the sensor output voltage is high. When the fuel level is low the sensor output voltage is low.
The PCM uses inputs from the Fuel Level sensor 1 and the Fuel Level sensor 2 in order to calculate the total fuel remaining in both fuel tanks. The system sends this information via the serial data to the IPC. This information displays on the fuel gauge.
When the PCM senses a signal voltage higher than the normal operating range of the sensor, this DTC sets.
The following is a description on how the fuel pump/system functions: An electric high pressure fuel pump attaches to the fuel sender assembly inside the left fuel tank. The fuel pump pumps fuel to the fuel rail assembly at a specified flow and pressure. Excess fuel from the fuel rail assembly returns to the left fuel tank through the return pipe. The fuel pump delivers a constant flow of fuel to the engine even during low fuel conditions and aggressive vehicle maneuvers. The PCM controls the electric fuel pump operation through a fuel pump relay.
The left tank fuel pump also supplies a small amount of pressurized fuel to the right fuel tank siphon jet pump through the fuel feed rear crossover pipe. The pressurized fuel creates a venturi action inside the siphon jet pump. The venturi action causes the fuel to be drawn out of the right fuel tank. Fuel is then transferred from the right fuel tank to the left fuel tank through the fuel sender fuel feed pipe. The fuel system is designed to maintain a greater level in the left fuel tank then the right fuel tank when the electric fuel pump is operating. The fuel transfer rate from the left fuel tank to the right fuel tank is less than the transfer rate from the right fuel tank to the left fuel tank. Therefore, with the electric fuel pump operating, the left fuel tank level should be higher than the right fuel tank level.
The fuel level in the fuel tanks equalize when the following occur:
- The electric fuel pump is not operating.
- The fuel level is greater than 50%.
Conditions for Running the DTC
The engine is operating.
Conditions for Setting the DTC
| • | The Fuel Level sensor 2 voltage above 2.9 volts. |
| • | The above condition present for greater than 20 seconds. |
Action Taken When the DTC Sets
| • | The powertrain control module (PCM) stores the DTC information into memory when the diagnostic runs and fails. |
| • | The malfunction indicator lamp (MIL) will not illuminate. |
| • | The PCM records the operating conditions at the time the diagnostic fails. The PCM stores this information in the Failure Records. |
Conditions for Clearing the DTC
| • | A last test failed, or current DTC, clears when the diagnostic runs and does not fail. |
| • | A history DTC will clear after 40 consecutive warm-up cycles, if no failures are reported by this or any other non-emission related diagnostic. |
| • | Use a scan tool in order to clear the DTC. |
Diagnostic Aids
Important:
• The PCM terminals C1-24 and C2-24 are the Sensor Ground Jumper
terminals. This DTC sets if the jumper is open or the connection between
the jumper and the PCM is faulty. Inspect for proper terminal tension/connections
at the PCM harness connector before replacing the PCM. • Depending on the current fuel level, it may be difficult to locate
a malfunctioning sending unit. The malfunction may only occur when the fuel
level is full or near empty. The fuel sending unit may need to be removed
for further diagnosis. A Fuel Level sensor that has an intermittent condition
causes this DTC to set. Remove the Fuel Level sensor refer to
Fuel Sender Assembly Replacement
in order to
check the resistance of the sensor. The resistance of the sensor
should change smoothly from 40ohms to 250ohms. Replace the sensor
if the resistance did not change smoothly or was out of range. • Remove any debris from the PCM\TAC module connector surfaces before
servicing the PCM\TAC module. Inspect the PCM\TAC module connector gaskets
when diagnosing/replacing the modules. Ensure that the gaskets
are installed correctly. The gaskets prevent contaminate intrusion
into the PCM\TAC modules.
The following occurs with this DTC set:
| • | The vehicle fuel gauge displays empty. |
| • | The Check Gauge lamp illuminates. |
| • | The Driver Information Center displays a message. |
The voltages in the Fuel Level Conversion Table are approximate values. Use this table to aid in diagnosis.
Fuel Level Conversion Table | ||
|---|---|---|
Approximate Values | ||
Fuel Level | Left Tank voltage | Right Tank Voltage |
100 % | 2.5 V | 2.5 V |
75 % | 2.5 V | 1.5 V |
50 % | 2.5 V | Less than 1.0 V |
25 % | 1.7 V | Less than 1.0 V |
0 % | Less than 1.0 V | Less than 1.0 V |
Using the Freeze Frame and/or Failure Records data may aid in locating an intermittent condition. If you cannot duplicate the DTC, the information included in the Freeze Frame and/or Failure Records data can help determine how many miles since the DTC set. The Fail Counter and Pass Counter can also help determine how many ignition cycles the diagnostic reported a pass and/or a fail. Operate vehicle within the same freeze frame conditions (RPM, load, vehicle speed, temperature etc.) that you observed. This will isolate when the DTC failed. For an intermittent condition, refer to Symptoms .
Test Description
The numbers below refer to the step numbers on the diagnostic table.
-
This step determines if the fault is present.
-
The PCM terminals C1-24 and C2-24 are the Sensor Ground Jumper terminals. This DTC sets if the jumper is open or the connection between the jumper and the PCM is faulty.
-
Inspect for proper terminal tension/connections at the PCM harness connector before replacing the PCM.
Step | Action | Value(s) | Yes | No |
|---|---|---|---|---|
1 | Did you perform the Powertrain On-Board Diagnostic (OBD) System Check? | -- | ||
2 |
Did DTC P1635 Fail This Ignition cycle? | -- | ||
Is the fuel level sensor right tank voltage above the specified value? | 2.9V | |||
4 |
Does the scan tool indicate that this diagnostic failed this ignition? | -- | Go to Diagnostic Aids | |
5 |
Is the Fuel Level Sensor Right Tank voltage below the specified value? | 1.0V | ||
6 | Probe the fuel level sensor right tank ground circuit with a test lamp J 35616-200 to B+. Does the test lamp illuminate? | -- | ||
7 |
Was the fuel level sensor right tank sensor signal circuit shorted? | -- | ||
8 | Measure the voltage at the fuel level sensor right tank 5.0 volt reference circuit to ground using a DMM J 39200 . Is the voltage greater than the specified value? | 5.1V | ||
9 |
Did the terminal require replacement? | -- | ||
10 |
Did the terminal require replacement? | -- | ||
11 |
Did you find and correct the condition? | -- | ||
Check the resistance between PCM connector terminals C1-24 and C2-24. Is the resistance within the specified range? | 0-5ohms | |||
13 | Repair the circuit with the high resistance. Refer to Body and Accessories/Wiring Systems . Is the action complete? | -- | -- | |
14 |
Did you find and correct the condition? | -- | ||
|
Important:: Program the replacement PCM. Refer to Powertrain Control Module/Throttle Actuator Control Module Replacement . Replace the PCM. Is the action complete? | -- | -- | ||
16 | Replace the fuel level sensor right tank. Refer to Fuel Sender Assembly Replacement . Is action complete? | -- | -- | |
17 | Repair the 5.0 volt reference circuit for a short to voltage. Is the action complete? | -- | -- | |
18 |
Does the scan tool indicate that this test ran and passed? | -- | ||
19 | Select the Capture Info option and the Review Info option using the scan tool. Are any DTCs displayed that have not been diagnosed? | -- | Go to the applicable DTC table | System OK |
