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Test Description

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

  1. 3:  This step tests for high resistance in the signal circuit and the low reference circuit of the fuel level sender.
  2. 13:  DTCs will be set in the PCM when you perform this diagnostic table.
Fuel Gage Inaccurate or Inoperative (Single Tank)

Step Action Value(s) Yes No
Schematic Reference: Instrument Cluster Schematics 
Connector End View Reference: Master Electrical Component List in Wiring Systems
1 Did you perform the Instrument Cluster Diagnostic System Check? - Go to Step 2  Go to Diagnostic System Check - Instrument Cluster 
2
  1. Disconnect C152.
  2. Connect the J 33431-C  Signal Generator and Instrument Panel Tester between the signal circuit of the fuel level sender and the low reference circuit of the fuel level sender (male terminal side). See Special Tools .
  3. Turn the ignition ON, with the engine OFF.
  4. Vary the resistance on the J 33431-C  from 40-250 ohms.
    IMPORTANT: Verify the J 33431-C  resistance settings with a DMM.
  5. Refer to Fuel Level Specifications  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 
  1. Install the scan tool.
  2. Turn the ignition ON, with the engine OFF.
  3. Vary the resistance on the J 33431-C  from 40-250 ohms. See Special Tools .
    IMPORTANT: Verify the J 33431-C  resistance settings with a DMM.
  4. Refer to Fuel Level Specifications  in order to convert from resistance to fuel level percent.
    5. IMPORTANT: Turn the ignition OFF momentarily between the resistance settings in order to quickly update the scan tool display.
  5. With the scan tool, observe one of the following fuel level parameters:
    • Fuel Tank Level Remaining parameter in the powertrain control module (PCM) Enhanced EVAP Data list - gas only
    • Fuel Level Sensor parameter in the PCM Fuel System data list - 6.6L diesel only
Does the scan tool display the correct fuel level percent?		 - Go to Step 11  Go to Step 5 
4 Inspect for the following items:
Did you find and correct the condition?		 - Go to Step 13  Go to Step 7 
5 Test the signal circuit of the fuel level sender for a high resistance between C152 and the PCM. Refer to Circuit Testing andWiring Repairs in Wiring Systems.
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 sender for a high resistance between C152 and the PCM. Refer to Circuit Testing and Wiring Repairs in Wiring Systems.
Did you find and correct the condition?		 - Go to Step 13  Go to Step 9 
7
  1. Remove the fuel level sender.
  2. Inspect for the following items:
    • A stuck fuel level sender, 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
  1. With the DMM, measure the resistance of the fuel level sender while moving the float arm.
  2. 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 PCM. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs in Wiring Systems.
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 procedures:
Did you complete the replacement?		 - Go to Step 13  -
11 Replace the instrument panel cluster (IPC). Refer to Instrument Panel Cluster (IPC) Replacement .
Did you complete the replacement?		 - Go to Step 13  -
12
IMPORTANT: Program the replacement PCM.
Replace the PCM. Refer to:Did you complete the replacement?		 - Go to Step 13  -
13 
  1. Use the scan tool in order to clear the PCM DTCs.
  2. Operate the system in order to verify the repair.
Did you correct the condition?		 - System OK Go to Step 2 
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