Test Description

The numbers below refer to the step numbers on the diagnostic table.

3: This step tests for a high resistance in the signal circuit and the low reference circuit of the fuel level sensor.
13: DTCs will be set in the ECM/PCM when you perform this diagnostic table.

Fuel Gage Inaccurate or Inoperative (2.0L and 2.2L)

Step	Action	Values	Yes	No
Schematic Reference: Instrument Cluster Schematics Connector End View Reference: Powertrain Control Module (PCM) Connector End Views for the 2.0L engine, Engine Control Module (ECM) Connector End Views for the 2.2L engine, or Engine Control Module (ECM) Connector End Views for the 2.4L engine
1	Did you perform the Diagnostic System Check - Vehicle?	-	Go to Step 2	Go to Diagnostic System Check - Vehicle
2	Disconnect C305. Connect the SA9205Z Signal Generator and Instrument Panel Tester between the signal circuit of the fuel level sensor and the low reference circuit of the fuel level sensor on the male terminal side. See Special Tools . Turn ON the ignition, with the engine OFF. IMPORTANT: Verify the SA9205Z resistance settings with a DMM. See Special Tools . Vary the resistance on the SA9205Z from 40-250 ohms. See Special Tools . Refer to Fuel Level Specifications (2.0L and 2.2L) or Fuel Level Specifications (2.4L) in order to convert from resistance to fuel gage display. Does the fuel gage display the correct fuel level?	-	Go to Step 4	Go to Step 3
3	Install a scan tool. Turn ON the ignition, with the engine OFF. IMPORTANT: Verify the SA9205Z resistance settings with a DMM. See Special Tools . Vary the resistance on the SA9205Z from 40-250 ohms. See Special Tools . Refer to Fuel Level Specifications (2.0L and 2.2L) or Fuel Level Specifications (2.4L) in order to convert from resistance to fuel level percent. IMPORTANT: Turn the ignition OFF momentarily between the resistance settings in order to quickly update the scan tool display. With the scan tool, observe the Fuel Tank Level Remaining parameter in the ECM/PCM EVAP Data List. Does the Fuel Tank Level Remaining parameter display the correct fuel level percentage?	-	Go to Step 11	Go to Step 5
4	Inspect for the following items: A poor connection at the harness connector of the fuel level sensor-Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs . A high resistance in the signal circuit or the low reference circuit between the fuel level sensor and C406 A misaligned fuel level sender A deformed fuel tank Did you find and correct the condition?	-	Go to Step 13	Go to Step 7
5	Test the signal circuit of the fuel level sensor for a high resistance. Refer to Circuit Testing and Wiring Repairs . Did you find and correct the condition?	-	Go to Step 13	Go to Step 6
6	Test the low reference circuit of the fuel level sensor for a high resistance. Refer to Circuit Testing and Wiring Repairs . Did you find and correct the condition?	-	Go to Step 13	Go to Step 9
7	Remove the fuel level sender. Inspect for the following items: A stuck fuel level sensor, i.e. the fuel strainer interfering with the sender float arm Foreign material in the fuel tank, i.e. ice Did you find and correct the condition?	-	Go to Step 13	Go to Step 8
8	With the DMM, measure the resistance of the fuel level sensor while moving the float arm. Observe both the analog and digital displays on the DMM. Does the resistance change smoothly across the specified range?	40-250 Ω	Go to Diagnostic Aids	Go to Step 10
9	Inspect for poor connections at the harness connector of the engine control module (ECM)/powertrain control module (PCM). Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs . Did you find and correct the condition?	-	Go to Step 13	Go to Step 12
10	Replace the fuel level sender. Refer to the following: Fuel Pump Module Replacement for the 2.0L engine Fuel Level Sensor Replacement for the 2.2L engine Fuel Level Sensor Replacement for the 2.4L engine Did you complete the replacement?	-	Go to Step 13	-
11	Replace the instrument panel cluster (IPC). Refer to Control Module References for replacement, setup, and programming. Did you complete the replacement?	-	Go to Step 13	-
12	Replace the ECM/PCM. Refer to Control Module References for replacement, setup, and programming. Did you complete the replacement?	-	Go to Step 13	-
13	Use the scan tool in order to clear the ECM/PCM DTCs. Operate the system in order to verify the repair. Did you correct the condition?	-	System OK	Go to Step 2