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Test F: Fuel Gauge Inoperative Or Inaccurate

  1. If Instrument Panel Cluster (IPC) diagnostic system check has not been performed, perform INSTRUMENT PANEL CLUSTER DIAGNOSTIC SYSTEM CHECK  under SELF-DIAGNOSTIC SYSTEM. If IPC diagnostic system check has been performed, go to next step.
    2. NOTE: Always verify resistance settings of Signal Generator and Instrument Panel Tester (J33431-C) using a DVOM, before connecting to vehicle.
  2. Turn ignition switch to OFF position. Disconnect in-line connector C305. In-line connector C305 is a Gray 12-pin Male connector connected to a Gray 4-pin Female connector and a Natural 8-pin Female connector. Connector C305 is located in body wiring harness, mounted as a pass-through under vehicle, behind back seat. See Figure . Using Signal Generator and Instrument Panel Tester (J33431-C), connect test leads to fuel level sender input (Purple wire) and fuel sender return (Dark Green wire) terminals on wiring harness side of fuel level sender connector. Observe fuel gauge. Vary tester resistance dial from 40-250 ohms. Fuel gauge indicator should read from "E" to "F". See Figure . Compare resistance readings to fuel gauge display. If fuel gauge readings are not as specified, go to next step. If fuel gauge readings are as specified, go to step  4 .
  3. Ensure ignition switch is in OFF position. Connect scan tool to Data Link Connector (DLC). DLC is located below left side of instrument panel, to right of steering column. See Figure . Turn ignition switch to RUN position, with engine off. Using scan tool, observe FUEL LEVEL percent in PCM EVAP data list. Vary tester resistance dial from 40-250 ohms. Compare resistance readings to scan tool display. See Figure . If scan tool does not display correct fuel level percentages for resistance settings, go to step  5 . If scan tool displays correct fuel level percentages for resistance settings, go to step  11 .
  4. Check for an intermittent condition, poor electrical connection or faulty wiring at harness connector for fuel sending unit. Check for an open or high resistance in Purple wire and Black wire between in-line connector C305 and fuel sending unit connector. Check for damaged or deformed fuel tank. If no problem is found, go to step  7 . If problem is found, repair as necessary. After repair, go to step  13 .
  5. Test Purple wire between fuel level sensor harness connector and PCM Clear harness connector C2 terminal No. 69 for high resistance. See Figure . If no problem is found, go to next step. If problem is found, repair as necessary. After repair, go to step  13 .
  6. Measure resistance of Black wire between fuel level sensor harness connector and PCM connector C2 terminal No. 35 for high resistance. If no problem is found, go to step  9 . If problem is found, repair as necessary. After repair, go to step  13 .
    7. NOTE: Fuel level sender is an integral part of fuel pump assembly.
  7. Remove fuel level sender from fuel tank. See FUEL PUMP under FUEL SYSTEM in appropriate REMOVAL, OVERHAUL & INSTALLATION article in ENGINE PERFORMANCE. Check for stuck fuel level sensor and for foreign material in fuel tank. If problem is not found, go to next step. If problem is found, repair as necessary. After repair, go to step  13 .
  8. Using DVOM, test resistance across fuel level sender terminals (component side) while moving float arm. If resistance changes smoothly from 40-250 ohms, go to DIAGNOSING INTERMITTENTS  . If resistance does not change smoothly from 40-250 ohms, go to step  10 .
  9. Check for poor connections at PCM harness connectors. If no problem is found, go to step  12 . If problem is found, repair as necessary. After repair go to step  13 .
  10. Replace fuel level sender. See FUEL PUMP under FUEL SYSTEM in appropriate REMOVAL, OVERHAUL & INSTALLATION article in ENGINE PERFORMANCE. After repair, go to step  13 .
  11. Replace IPC. See INSTRUMENT PANEL CLUSTER  under REMOVAL & INSTALLATION. After repair, go to step  13 .
  12. Replace PCM. See POWERTRAIN CONTROL MODULE  under REMOVAL & INSTALLATION. After repair, go to next step.
  13. Using scan tool, clear PCM DTCs. Operate system to verify repair. If system does not operate properly, go to step  2 . If system operates properly, system is okay.
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