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Test D: Fuel Gauge Inaccurate Or Inoperative: Testing

  1. If diagnostic system check has been performed, go to next step. If diagnostic system check has not been performed, perform INSTRUMENT CLUSTER DIAGNOSTIC SYSTEM CHECK  under SELF-DIAGNOSTIC SYSTEM.
    2. NOTE: Verify Signal Generator and Instrument Panel Tester (J33431-C) resistance settings with Digital Volt/Ohmmeter (DVOM).
  2. Turn ignition switch to OFF position. Disconnect 7-pin in-line harness connector C405B from in-line harness connector C405A. In-line harness connector is located forward of rear axle. Using Signal Generator and Instrument Panel Tester (J33431-C), connect one lead to fuel level sensor harness connector C405B terminal 3A (Purple wire) and other lead to instrument panel harness connector C405A terminal 3C (male side). Turn ignition switch to RUN position. Vary resistance on Signal Generator and Instrument Panel Tester (J33431-C) from 40 to 250 ohms. Fuel gauge should vary level settings with resistance. See FUEL LEVEL SPECIFICATIONS  table. If fuel gauge does not display as specified, go to next step. If fuel gauge displays as specified, go to step  4.
    FUEL LEVEL SPECIFICATIONS

    Fuel Gauge Display Resistance Fuel Level
    "E" 40-82 Ohms 0-11%
    1/4 130 Ohms 30%
    1/2 165 Ohms 48%
    3/4 199 Ohms 69%
    "F" 227-250 Ohms 88-100%
    Check Gauges Indicator On 90 Ohms 15%
    3. NOTE: Verify Signal Generator and Instrument Panel Tester (J33431-C) resistance settings with DVOM.
  3. Turn ignition switch to OFF position. Connect scan tool to Data Link Connector (DLC). DLC is located below left side of instrument panel, to right of steering column. Turn ignition switch to RUN position. Vary resistance on Signal Generator and Instrument Panel Tester (J33431-C) from 40 to 250 ohms. Momentarily turn ignition switch to OFF position to update scan tool display. Using scan tool, observe fuel level percentage parameter in Powertrain Control Module (PCM) EVAP data list. See SCAN TOOL DATA LIST  table. If scan tool does not display correct fuel level percentage, go to step  5. If scan tool displays correct fuel level percentage, go to step  11.
    SCAN TOOL DATA LIST

    Scan Tool Parameter Data List Units Displayed Typical Data Value
    Engine Oil Level Switch Engine Data 2 OK/Low OK
    Fuel Tank Level Remaining EVAP Data % 0-100% Varies
    Vehicle Speed Sensor Engine Data 1 MPH 0 MPH
  4. Inspect fuel level sensor harness connector for poor connections. Inspect Purple wire and Black wire for high resistance between fuel tank unit and in-line harness connector C405A. Inspect for misaligned fuel level sensor or deformed fuel tank. If all components are okay, go to step  7. If any components are not okay, repair as necessary then go to step  13.
  5. Inspect Purple wire for a high resistance between fuel level sensor harness connector terminal "A" and in-line harness connector C405B terminal 3A. If a high resistance is not found, go to next step. If a high resistance found, repair as necessary then go to step  13.
  6. Inspect Black wire for a high resistance between ground and fuel level sensor harness connector terminal "C". If a high resistance is not found, go to step  9. If a high resistance is found, repair as necessary then go to step  13.
  7. Remove fuel level sensor from fuel pump unit. Inspect for stuck fuel strainer interfering with float arm, or foreign material in fuel tank. If all components are okay, go to next step. If any component is not okay, repair as necessary then go to step  13.
  8. Using Digital Volt/Ohmmeter (DVOM), measure resistance between fuel level sensor terminals (component side) while moving float arm assembly. Resistance should vary between 40 and 250 ohms. If resistance is as specified, refer to DIAGNOSTIC AIDS . If resistance is not as specified, go to step  10.
  9. Disconnect PCM 80-pin harness connector. PCM is located on right side of engine compartment, near rear of wheelwell. Inspect PCM harness connector for poor connections. If connections are okay, go to step  12. If connections are not okay, repair as necessary then go to step  13.
  10. Replace fuel level sensor, then go to step  13.
  11. Replace Instrument Panel Cluster (IPC). Program IPC. See INSTRUMENT PANEL CLUSTER  under PROGRAMMING. After replacement, go to step  13.
  12. Replace PCM. Program PCM. See POWERTRAIN CONTROL MODULE  under PROGRAMMING. After replacement, go to next step.
  13. Using scan tool, clear DTCs. Operate system to verify repair. If condition has been corrected, system is operating correctly at this time. If condition has not been corrected, repeat test procedure beginning at step  2.
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