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Fuel Gauge Inoperative Or Inaccurate

  1. If instrument panel cluster diagnostic check was performed, go to next step. If instrument panel cluster diagnostic check was not performed, go to INSTRUMENT PANEL CLUSTER DIAGNOSTIC SYSTEM CHECK  under SELF-DIAGNOSTIC SYSTEM.
  2. Disconnect fuel lever sender harness connector. Connect Signal Generator and Instrument Panel Tester (J33431-C) between the signal circuit and low reference circuit of the fuel level sender at the fuel sender harness connector. Turn ignition switch to ON position. Vary resistance 40-250 ohms. See FUEL LEVEL SENDER RESISTANCE  table. If fuel gauge indication does not agree with expected resistances, go to next step. If fuel gauge indication agrees with expected resistances, go to step  4.
  3. Connect scan tool to Data Link Connector (DLC). Vary resistance 40-250 ohms. If scan tool does not display correct fuel lever percentages, go to step  5. If scan tool displays corrects fuel level percentages, go to step  11.
  4. Check for poor connection at fuel level sender, misaligned fuel level sender and/or deformed fuel tank. Repair or replace as necessary. After repair, check system for normal operation. If no problems were found, go to  7.
  5. Check fuel level sender signal circuit for high resistance. Repair circuit as necessary. If no problem was found, go to next step.
  6. Check fuel level sender low reference circuit for high resistance. Repair circuit as necessary. If no problem was found, go to step  9.
  7. l sender from fuel tank. Inspect for obstruction to float arm, faulty float or foreign material in tank. Repair or replace as necessary. After repair, check system for normal operation. If no problem is found, go to next step.
  8. Measure resistance of fuel level sender while moving float arm through full travel. Observe both analog and digital displays. See FUEL LEVEL SENDER RESISTANCE  table. If resistances vary smoothly through expected range, problem is intermittent. Check for poor connections, damaged wiring or improper installation. Repair as necessary. After repair, check system for normal operation. If resistances doe not vary smoothly through expected range, go to step  10.
  9. Check for poor connection or connector damage at PCM harness connector. Repair or replace as necessary. After repair, check system for normal operation. If connection is okay, go to step  12.
  10. Replace fuel level sender. After repair, check system for normal operation.
  11. Replace IPC. See INSTRUMENT PANEL CLUSTER (IPC)  under REMOVAL & INSTALLATION. After repair, check system for normal operation.
  12. Replace PCM. See appropriate REMOVAL & INSTALLATION article in ENGINE PERFORMANCE. After repair, check system operation and go to next step.
  13. Using scan tool, clean all PCM DTCs. Operate vehicle to verify repairs. If no problem is found, repairs are complete. If condition still exists, return to step  2.
FUEL LEVEL SENDER RESISTANCE

Fuel Gauge Indication Ohms
Empty 40-62
1/4 95
1/2 125
3/4 156
Full 201-250
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