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DTC P2635:00 [PCM (SKYACTIV-D)]

DTC P2635:00 [PCM (SKYACTIV-D)]

 id0102t5520200

Note
•  To determine the malfunctioning part, proceed with the diagnostics from "Function Inspection Using M-MDS".

Details On DTCs

Description

Fuel transfer function malfunction
Detection condition
Determination conditions
•  After the vehicle is sufficiently fueled, the PCM detects that fuel in the fuel tank (sub) does not decrease and only the fuel in the fuel tank (main) decreases continuously for the specified number of times.
Preconditions
•  1 min have elapsed after the ignition was switched ON (engine off)
•  The following DTCs are not detected:
―  P0462:00, P0463:00, U0121:00 or U0140:00
Drive cycle
•  2*
*: Because the PCM monitors the fuel decrease transition after the vehicle is sufficiently fueled, two or more drive-cycles may be necessary to store a DTC depending on the driving conditions.
Self test type
•  CMDTC self test
Sensor used
•  Fuel gauge sender unit
Fail-safe function
•  Not applicable
Vehicle status when DTCs are output
•  If the fuel tank (main) becomes empty, rough idling, poor acceleration, and engine stalling occur.
Possible cause
•  Fuel system malfunction
―  Dirty fuel
―  Jet pump (built-into fuel pump unit) malfunction
―  Fuel gauge sender unit malfunction
―  Fuel tank malfunction
•  Clogging in hose between fuel tank (main) and fuel tank (sub)
•  Disconnected hose between fuel tank (main) and fuel tank (sub)
•  Quick release connector poor connection
―  Supply pump malfunction
•  PCM malfunction


System Wiring Diagram

•  Not applicable

Function Explanation (DTC Detection Outline)

•  The fuel tanks of AWD vehicles have a saddle-like shape, with a main side and sub side.
•  The PCM monitors the fuel levels in the fuel tank (main) and fuel tank (sub).
•  If the fuel transfer function is malfunctioning, fuel cannot be transferred from the fuel tank (sub) to the fuel tank (main) and only the fuel in the fuel tank (main) decreases.
•  The PCM determines that the above condition is a malfunction, and stores a DTC.

Repeatability Verification Procedure

•  Not applicable
Note
•  The PCM monitors the fuel consumption in the fuel tanks (main and sub). Therefore, a certain amount of fuel needs to be consumed. It is not recommended to verify the recurrence of this DTC after the vehicle is repaired.

PID Item/Simulation Item Used In Diagnosis

•  Not applicable

Function Inspection Using M-MDS

Step

Inspection

Results

Action
1
PURPOSE: VERIFY RELATED REPAIR INFORMATION OR SERVICE INFORMATION AVAILABILITY
•  Verify related Service Bulletins, on-line repair information, or Service Information availability.
•  Is any related Information available?
Yes
Perform repair or diagnosis according to the available information.
•  If the vehicle is not repaired, go to the next step.
No
Go to the next step.
2
PURPOSE: RECORD VEHICLE STATUS WHEN DTC WAS DETECTED TO UTILIZE WITH REPEATABILITY VERIFICATION
•  Record the freeze frame data/snapshot data.
Note
•  Recording can be facilitated using the screen capture function of the PC.
—
Go to Troubleshooting Diagnostic Procedure to perform the procedure from Step 1.


Troubleshooting Diagnostic Procedure

Intention of troubleshooting procedure
•  Step 1
―  Verify if fuel in the fuel tank is dirty.
•  Step 2
―  Perform a unit inspection of the fuel gauge sender unit.
―  Perform the jet pump inspection together with the fuel gauge sender unit inspection.
•  Step 3
―  Inspect the hose between the fuel tank (main) and the fuel tank (sub).
•  Step 4
―  Perform a unit inspection of quick release connector installation condition
―  Perform a unit inspection of the fuel tank.
•  Step 5
―  Perform a unit inspection of the supply pump.
•  Repair completion verification
―  Verify that the primary malfunction is resolved and there are no other malfunctions.

Step

Inspection

Results

Action
1
PURPOSE: VERIFY IF FUEL IN FUEL TANK IS DIRTY, AND FUEL FILTER CONDITION
•  Inspect the applicable parts.
―  Dirty fuel
―  Fuel filter clogging
•  Is the part normal?
Yes
Go to the next step.
No
Clean the inside of the fuel tank.
Repair or replace the malfunctioning location and perform the repair completion verification.
(See FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)
(See FUEL FILTER REPLACEMENT [SKYACTIV-D 1.8].)
2
PURPOSE: INSPECT FUEL GAUGE SENDER UNIT AND JET PUMP FOR MALFUNCTION
•  Inspect the applicable parts.
―  Fuel gauge sender unit
―  Jet pump
•  Is the part normal?
Yes
Go to the next step.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
(See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [(E)].)
3
PURPOSE: VERIFY CONDITION INSIDE FUEL TANK
•  Remove the fuel tank.
•  Inspect the applicable parts.
―  Poor connection of hose between fuel tank (main) and fuel tank (sub)
―  Breakage or bending of hose between fuel tank (main) and fuel tank (sub)
•  Is the part normal?
Yes
Go to the next step.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
(See FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)
4
PURPOSE: INSPECT HOSE BETWEEN FUEL TANK (MAIN) AND FUEL TANK (SUB) FOR MALFUNCTION
•  Perform the following procedure.
1.  Remove the fuel tank (main) quick release connector and the fuel tank (sub) quick release connector.
2.  Verify the airflow by blowing air through the hose.
•  Is there any clogging in the hose?
Yes
Go to the next step.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
(See QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)
(See FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)
5
PURPOSE: INSPECT SUPPLY PUMP FOR MALFUNCTION
•  Inspect the applicable parts.
―  Supply pump
•  Is the part normal?
Yes
Go to the next step.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
(See SUPPLY PUMP REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)
Repair completion verification 1
PURPOSE: VERIFY THAT VEHICLE IS REPAIRED
•  Install/connect the part removed/disconnected during the troubleshooting procedure.
•  Clear the DTC recorded in the memory.
•  Replicate the vehicle conditions at the time the DTC was detected using the following procedure.
―  Implement the repeatability verification procedure.
―  Refill the fuel.
•  Perform the DTC inspection for the PCM.
•  Is the same Pending DTC present?
Yes
Refer to the controller area network (CAN) malfunction diagnosis flow to inspect for a CAN communication error.
(See CONTROLLER AREA NETWORK (CAN) MALFUNCTION DIAGNOSIS FLOW [(E)].)
If the CAN communication is normal, perform the diagnosis from Step 1.
•  If the malfunction recurs, replace the PCM, then go to the next step.
No
Go to the next step.
Repair completion verification 2
PURPOSE: VERIFY IF OTHER DTCs DISPLAYED
•  Perform the DTC inspection.
•  Are any other DTCs displayed?
Yes
Repair the malfunctioning location according to the applicable DTC troubleshooting.
No
DTC troubleshooting completed.