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Test 3: Fuel Gauge Inaccurate/Inoperative

  1. If instrument cluster diagnostic system check has been performed, go to next step. If instrument cluster diagnostic system check has not been performed, perform instrument cluster diagnostic system check. See INSTRUMENT CLUSTER DIAGNOSTIC SYSTEM CHECK  under SELF-DIAGNOSTIC SYSTEM.
  2. Turn ignition off. Disconnect fuel tank module harness connector. Using Instrument Panel Tester (J-33431-C), connect one lead to terminal "A" (Purple wire) and connect other lead to terminal "D" at fuel tank module harness connector. Turn ignition on. Move tester resistance dial to appropriate position while observing fuel gauge. See TESTER RESISTANCE VALUES  table. If fuel gauge operates as specified, go to step  4 . If fuel gauge does not operate as specified, go to next step.
    3. NOTE: Turn ignition off between resistance setting to quickly update scan tool display.
  3. Turn ignition off. Connect scan tool to Data Link Connector (DLC). Turn ignition on. Using scan tool, observe FUEL LEVEL % parameter in Powertrain Control Module (PCM) EVAP data list while moving tester resistance dial to appropriate position. See TESTER RESISTANCE VALUES  table. If scan tool display does not agree with tester resistance setting, go to step  5 . If scan tool display agree with tester resistance setting, go to step  11 .
  4. Check for an open in Purple wire and/or Black/White wire between fuel tank module and PCM. Check for damage fuel tank. Check for damaged or misadjusted fuel level sensor. If problem exists, repair as necessary, then go to step  13 . If circuit is okay, go to step  7 .
  5. Check for open in Purple wire between fuel tank module and PCM. If problem exists, repair as necessary and go to step  13 . If circuit is okay, go to next step.
  6. Check for open in Black/White wire between fuel tank module and PCM. If problem exists, repair as necessary and go to step  13 . If circuit is okay, go to step  9 .
  7. Check fuel level sensor for sticking and damage. Check for foreign material in fuel tank. If problem exists, repair as necessary and go to step  13 . If problem does not exist, go to next step.
  8. Remove fuel tank module. Measure resistance between terminals "A" and "D" at fuel tank module (component side). Resistance should be 40 ohms with float in empty position and 250 ohms with float in full position. Resistance should change smoothly between both positions. If resistance is as specified, check for poor connections and intermittent conditions. If resistance is not as specified, go to step  10 .
  9. Check for poor connection and PCM. If problem exists, repair as necessary and go to step  13 . If problem does not exist, go to step  12 .
  10. Replace fuel tank module. After repairs, go to step  13 .
  11. Replace instrument cluster. After repairs, go to step  13 .
  12. Replace PCM and program PCM. For programming procedure, see COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION. After repairs, go to next step.
  13. Using scan tool, clear DTCs. Operate system. If problem still exists, go to step  2 .
TESTER RESISTANCE VALUES

Fuel Gauge Display Tester Resistance Value Scan Tool Percentage
Plastic Tank
Empty 40-45 2-4
1/4 90 21
1/2 129 40
3/4 164 60
Full 207-250 79-93
CHECK GAUGES Indicator On 47 4
Steel Tank
Empty 40-50 1-3
1/4 109 22
1/2 153 44
3/4 192 66
Full 250 89
CHECK GAUGES Indicator On 58 4
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