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Test B: Fuel Gauge Inaccurate/Inoperative: Notes

  1. If instrument panel cluster diagnostic system check has been performed, go to next step. If instrument panel cluster diagnostic system check has not been performed, go to INSTRUMENT PANEL CLUSTER DIAGNOSTIC SYSTEM CHECK  under SELF-DIAGNOSTIC SYSTEM.
    2. NOTE: Verify Signal Generator and Instrument Panel Tester (J-33431-C) resistance with DVOM.
  2. Turn ignition to LOCK position. Disconnect in-line harness connector C313. In-line harness connector C313 is located on fuel tank. Connect Signal Generator and Instrument Panel Tester (J-33431-C) leads to in-line harness connector C313 terminal D3 (Purple wire; female terminal) and terminal B3 (Black/White wire; male terminal). See Figure. Turn ignition switch to RUN position. Vary resistance on tester from 40-250 ohms. See FUEL LEVEL SPECIFICATIONS  table. If fuel gauge does not display correct fuel level, go to next step. If fuel gauge displays correct fuel level, go to step  4.
    3. NOTE: Verify Signal Generator and Instrument Panel Tester (J-33431-C) resistance with DVOM.
    NOTE: Turn ignition switch to LOCK position between resistance settings to quickly update scan tool display.
  3. Turn ignition to LOCK position. Connect scan tool to Data Link Connector (DLC). DLC is located at lower left side of instrument panel, near steering column. Turn ignition to RUN position. Vary resistance on tester from 40-250 ohms. See FUEL LEVEL SPECIFICATIONS  table. Using scan tool, observe FUEL LEVEL % parameter in PCM EVAP data list. If scan tool does not display correct fuel level percent, go to step  5. If scan tool displays correct fuel level percent, go to step  11.
  4. Check for poor connections at fuel level sensor harness connector. Check for high resistance in Purple wire between in-line harness connector C313 terminal D3 and fuel level sensor. Check for high resistance in Black/White wire between in-line harness connector C313 terminal B3 and fuel level sensor. Check for misaligned fuel level sender or deformed fuel tank. If problem is not found, go to step  7. If problem is found, repair as necessary. After repairs, go to step  13.
  5. Check for high resistance in Purple wire between in-line harness connector C313 terminal D3 and PCM. See Figure. If problem is not found, go to next step. If problem is found, repair Purple wire. After repairs, go to step  13.
  6. Check for high resistance in Black/White wire between in-line harness connector C313 terminal B3 and PCM. If problem is not found, go to step  9. If problem is found, repair Purple wire. After repairs, go to step  13.
  7. Remove fuel level sensor from fuel tank. Check fuel level sensor for sticking and damage. Check for foreign material in fuel tank. If problem is not found, go to next step. If problem is found, repair as necessary. After repairs, go to step  13.
  8. Measure resistance between terminals at fuel tank level sensor (component side) while moving float arm from empty to full positions. Resistance should change smoothly from 40-250. If resistance does not change as specified, go to step  10. If resistance changes as specified, go to DIAGNOSTIC AIDS .
  9. Check for poor connection at PCM. If problem is not found, go to step  12. If problem is found, repair as necessary. After repairs, go to step  13.
  10. Replace fuel level sensor. See FUEL PUMP in REMOVAL, OVERHAUL & INSTALLATION - CARS article under ENGINE PERFORMANCE. For 2002, see FUEL PUMP in REMOVAL, OVERHAUL & INSTALLATION - CARS article under ENGINE PERFORMANCE. After repairs, go to step  13.
  11. Replace instrument cluster. See INSTRUMENT CLUSTER  under REMOVAL & INSTALLATION. After repairs, go to step  13.
  12. Replace and program PCM. See POWERTRAIN CONTROL MODULE  under REMOVAL & INSTALLATION. See POWERTRAIN CONTROL MODULE PROGRAMMING . After repairs, go to next step.
  13. Check system for proper operation. If system operates properly, test is complete. If system does not operate properly, go to step  2.
FUEL LEVEL SPECIFICATIONS

Fuel Gauge Display Tester Resistance Value Scan Tool Percentage Remaining Fuel
 
Gal (L)
Empty 40-45 2-4 .5-1 (2-4)
1/4 90 21 4.4 (16.6)
1/2 129 40 7.8 (29.3)
3/4 164 60 10.6 (40.3)
Full 207-250 79-100 13.8-14.3 (52.4-54.1)
CHECK GAUGES Indicator On 47 5 1.3 (4.9)
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