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Test C: Fuel Gauge Inaccurate Or Inoperative

  1. If Instrument Panel Cluster (IPC) diagnostic system check has been performed, go to next step. If IPC diagnostic system check has not been performed, see INSTRUMENT PANEL CLUSTER DIAGNOSTIC SYSTEM CHECK  under SELF-DIAGNOSTIC SYSTEM.
  2. Turn ignition switch to OFF position. Disconnect connector C104. Connect Signal Generator and Instrument Panel Tester (J33431-C) between connector C104 terminal "E" (Purple wire) and terminal "D" (Orange/Black wire on 2.2L engines, Black wire on 4.3L engines). See Figure . Turn ignition switch to ON position. Vary resistance on J33431-C while observing fuel gauge on IPC. When resistance is near 40 ohms, fuel gauge should read EMPTY. When resistance is near 250 ohms, fuel gauge should read FULL. If operation is as specified, go to step  4 . If resistance is not as specified, go to next step.
  3. Turn ignition switch to OFF position. Connect scan tool to DLC. Turn ignition switch to ON position. Vary resistance on J33431-C while observing FUEL TANK LEVEL REMAINING parameter in PCM data list. See FUEL TANK LEVEL SPECIFICATIONS  table. If FUEL TANK LEVEL REMAINING parameter is according to specification, go to step  11 . If parameter is not as specified, go to step  5 .
  4. Turn ignition switch to OFF position. Disconnect fuel level sensor electrical connector, then remove fuel level sensor from vehicle. See REMOVAL, OVERHAUL & INSTALLATION - TRUCKS article in ENGINE PERFORMANCE. Inspect fuel level sensor for misalignment or deformation in fuel tank. On 2.2L engines, check Orange/Black wire between fuel level sensor connector terminal No. 4 and connector C104 terminal "D". See Figure . See WIRING DIAGRAMS  . On 4.3L engines, check Black/White wire between fuel level sender connector terminal "D" and connector C104 terminal "D". See Figure . See WIRING DIAGRAMS  . On all vehicles, check Purple wire between connector C104 terminal "E" and fuel level sender unit connector terminal No. 2 (2.2L engines) or terminal "A" (4.3L engines). Check all wiring for high resistance or open circuit. Repair as necessary, then go to step  13 . If no problems are found, go to step  7 .
  5. On 2.2L engines, check Purple wire between PCM connector C1 terminal No. 55 and fuel level sender connector terminal No. 2. See Figure and Figure . See WIRING DIAGRAMS  . On 4.3L engines, check Purple wire between PCM connector C2 terminal No. 54 and fuel level sender connector terminal "A". See Figure and Figure . See WIRING DIAGRAMS  . On all vehicles, check circuit for open or high resistance. Repair wiring as necessary, then go to step  13 . If no problems are found, go to next step.
  6. On 2.3L engines, check Orange/Black wire between fuel level sender connector terminal No. 4 and PCM connector C1 terminal No. 6. See WIRING DIAGRAMS  . On 4.3L engines, check Black/White wire between fuel level sender connector terminal "D" and connector C104 terminal "D", then check Black wire between connector C104 and PCM connector C1 terminal No. 23. See WIRING DIAGRAMS  . On all models, check circuit of high resistance or open. Repair wiring as necessary, then go to step  13 . If no problems are found, go to step  9 .
  7. Check fuel level sender for mechanical fault or damaged level arm. Check fuel tank for foreign material. Repair as necessary, then go to step  13 . If no problems are found, go to next step.
  8. Connect DVOM between fuel level sender terminals No. 2 and 4 (2.2L engines) or terminals "A" and "D" (4.3L engines). Monitor resistance while moving level arm. If resistance changes smoothy as arm is moved, system is functioning properly at this time. Check connections and wiring for intermittent faults. See WIRING DIAGRAMS  . If resistance does not vary smoothly as level arm is moved, go to step  10 .
  9. Check PCM connector for poor connection or corroded terminals. Repair connector as necessary, then go to step  13 . If no problems are found, go to step  12 .
  10. Replace fuel level sensor. See REMOVAL, OVERHAUL & INSTALLATION - TRUCKS article in ENGINE PERFORMANCE. When repair is complete, go to step  13 .
  11. Replace IPC. See INSTRUMENT PANEL CLUSTER  . When repair is complete, go to step  13 .
  12. Replace PCM. See REMOVAL, OVERHAUL & INSTALLATION - TRUCKS article in ENGINE PERFORMANCE. When repair is complete, go to next step.
  13. Using scan tool, clear PCM DTCs. Operate vehicle to verify proper fuel gauge operation. If fuel gauge operation is normal, repair is complete. If fuel gauge operation is faulty, go to step  2 .
FUEL TANK LEVEL SPECIFICATIONS

Application Resistance (Ohms) Fuel Remaining Percentage
18 Gallon Tank (4-Door Utility) 48-63 2-15
88-99 33-38
122-132 53-58
155-165 68-78
210-235 90-95
19 Gallon Tank (2-Door Utility 55-60 11-16
98-103 35-40
130-135 55-60
174-179 77-82
200-235 90-100
18.5 Gallon Tank (Pickup) 48-63 11-16
82-86 35-40
122-126 55-60
164-168 77-82
226-230 90-100
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