INSPECTION PROCEDURE 9: Fuel gauge does not work (other meters work): Diagnosis

Required Special Tools: 

• MB991958: Scan Tool (M.U.T.-III Sub Assembly)
  • MB991824: V.C.I.
  • MB991827: M.U.T.-III USB Cable
  • MB991910: M.U.T.-III Main Harness A
• MB991223: Harness Set
• MB992006: Extra Fine Probe

1. STEP 1. Using scan tool MB991958, check data list. 
   CAUTION: To prevent damage to scan tool MB991958, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991958.
   1. Connect scan tool MB991958 to the data link connector.
   2. Start the engine.
   3. Set scan tool MB991958 to the data reading mode.
      • Item 06: fuel gauge (Input).
        • Fuel gauge unit resistance value and M.U.T.-III displayed value should agree with each other.
      • Item 07: fuel gauge (Target).
        • Fuel gauge and M.U.T.-III displayed values should agree with each other.
   4. Turn the ignition switch to the "LOCK" (OFF) position.

   Q: Is the check result normal? 

   YES:  Go to Step  2.

   NO:  Go to Step  3.

   Fig 1: Connecting Scan Tool To Data Link Connector

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2. STEP 2. Using scan tool MB991958, check actuator test. 
   1. Turn the ignition switch to the "ON" position.
   2. Set scan tool MB991958 to the actuator test mode.
      • Item 11: fuel gauge (Target) : 0%
        • Fuel gauge shows 0 %
      • Item 8D: fuel gauge (Target) : 50%
        • Fuel gauge shows 50 %
      • Item 8E: fuel gauge (Target) : 100%
        • Fuel gauge shows 100 %
   3. Turn the ignition switch to the "LOCK" (OFF) position.

   Q: Is the check result normal? 

   YES:  An intermittent malfunction is suspected. Refer to "How to Use Troubleshooting/inspection Service Points - HOW TO COPE WITH INTERMITTENT MALFUNCTIONS " .

   NO:  Replace the combination meter.

   Fig 2: Connecting Scan Tool To Data Link Connector

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3. STEP 3. Check fuel level sensor (sub) connector D-10 for loose, corroded or damaged terminals, or terminals pushed back in the connector. 

   Q: Is fuel level sensor (sub) connector D-10 in good condition? 

   YES:  Go to Step  4.

   NO:  Repair or replace the damaged component(s). Refer to HARNESS CONNECTOR INSPECTION . The combination meter works normally.

   Fig 3: Locating Fuel Level Sensor Connector D-10 (Eclipse)

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   Fig 4: Locating Fuel Level Sensor Connector D-10 (Eclipse Spyder)

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4. STEP 4. Check the fuel level sensor (sub). 

   Check to see if the fuel level sensor (sub) is normal. Refer to FUEL LEVEL SENSOR CHECK .

   Q: Is the fuel level sensor (sub) normal? 

   YES:  Go to Step  5.

   NO:  Replace the fuel level sensor (Refer to FUEL TANK ).

5. STEP 5. Check fuel pump module connector D-19 for loose, corroded or damaged terminals, or terminals pushed back in the connector. 

   Q: Is fuel pump module connector D-19 in good condition? 

   YES:  Go to Step  6.

   NO:  Repair or replace the damaged component(s). Refer to HARNESS CONNECTOR INSPECTION . Verify that the combination meter works normally.

   Fig 5: Locating Fuel Pump Module Connector D-19 (Eclipse)

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   Fig 6: Locating Fuel Pump Module Connector D-19 (Eclipse Spyder)

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6. STEP 6. Check the fuel pump module. 

   Check to see if the fuel pump module is normal. Refer to FUEL LEVEL SENSOR CHECK .

   Q: Is the fuel pump module normal? 

   YES:  Go to Step  7.

   NO:  Replace the fuel pump module (Refer to FUEL TANK ). The fuel gauge should now operate normally.

7. STEP 7. Check the ground circuit to the fuel level sensor (sub). Measure the resistance at fuel level sensor (sub) connector D-10. 
   1. Disconnect fuel level sensor (sub) connector D-10 and measure the resistance available at the harness side of the connector.
      Fig 7: Locating Fuel Level Sensor Connector D-10 (Eclipse)

      Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
      Fig 8: Locating Fuel Level Sensor Connector D-10 (Eclipse Spyder)

      Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
   2. Measure the resistance value between terminal 1 and ground.
      • The resistance should be 2 ohms or less.

   Q: Is the measured resistance 2 ohms or less? 

   YES:  Go to Step  8.

   NO:  Go to Step  12.

   Fig 9: Measuring Resistance Value Between Terminal 1 And Ground

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8. STEP 8. Check ECM < M/T> or PCM < A/T> connector B-19 for loose, corroded or damaged terminals, or terminals pushed back in the connector. 

   Q: Is ECM < M/T> or PCM < A/T> connector B-19 in good condition? 

   YES:  Go to Step  9.

   NO:  Repair or replace the damaged component(s). Refer to HARNESS CONNECTOR INSPECTION . Verify that the combination meter works normally.

   Fig 10: Identifying Connector B-19 Terminals

   Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
9. STEP 9. Check the wiring harness between fuel level sensor (sub), the fuel pump module and the ECM < M/T> or PCM < A/T> for short to ground. Measure the resistance at fuel level sensor (sub) connector D-10. 
   1. Disconnect ECM < M/T> or PCM < A/T> connector B-19, fuel level sensor (sub) connector D-10 and fuel pump module connector D-19, and measure the resistance available at the harness side of the fuel level sensor (sub) connector D-10.
      Fig 11: Identifying Connector B-19 Terminals

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      Fig 12: Locating Fuel Level Sensor Connector D-10 And Fuel Pump Module Connector D-19 (Eclipse)

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      Fig 13: Locating Fuel Level Sensor Connector D-10 And Fuel Pump Module Connector D-19 (Eclipse Spyder)

      Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
   2. Measure the resistance between fuel level sensor (sub) connector D-10 terminal 1 and ground.
      • The resistance should be 1 kΩ or more.

   Q: Is the measured resistance 1 kΩ or more? 

   YES:  Replace ECM < M/T> or PCM < A/T>. When the ECM < M/T> or PCM < A/T> is replaced, register the encrypted code. Refer to ENCRYPTED CODE REGISTRATION CRITERIA TABLE  .

   NO:  Go to Step  10.

   Fig 14: Measuring Resistance Between Fuel Level Sensor (Sub) Connector D-10 Terminal 1 And Ground

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10. STEP 10. Check the wiring harness between fuel level sensor (sub) connector D-10 (terminal 1) and fuel pump module connector D-19 (terminal 2). 

    Q: Is the wiring harness between fuel level sensor connector D-10 (terminal 1) and fuel pump module connector D-19 (terminal 2) in good condition? 

    YES:  Go to Step  11.

    NO:  The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. Verify that the combination meter works normally.

    Fig 15: Locating Fuel Level Sensor Connector D-10 And Fuel Pump Module Connector D-19 (Eclipse)

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    Fig 16: Locating Fuel Level Sensor Connector D-10 And Fuel Pump Module Connector D-19 (Eclipse Spyder)

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
11. STEP 11. Check the wiring harness between fuel level sensor (sub) connector D-10 (terminal 1) and ECM < M/T> or PCM < A/T> connector B-19 (terminal 24). 
    Fig 17: Identifying Connector B-19 Terminals

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    Fig 18: Locating Fuel Level Sensor Connector D-10 (Eclipse)

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    Fig 19: Locating Fuel Level Sensor Connector D-10 (Eclipse Spyder)

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    NOTE: Also check intermediate connector C-26 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connector C-26 is damaged, repair or replace the damaged component(s) as described in HARNESS CONNECTOR INSPECTION .

    Q: Is the wiring harness between fuel level sensor connector D-10 (terminal 1) and ECM < M/T> or PCM < A/T> connector B-19 (terminal 24) in good condition? 

    YES:  An intermittent malfunction is suspected. Refer to "How to Use Troubleshooting/inspection Service Points - HOW TO COPE WITH INTERMITTENT MALFUNCTIONS " .

    NO:  The wiring harness may be damaged or the connector(s) may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. Verify that the combination meter works normally.

    Fig 20: Identifying C-26 Connector Terminals

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12. STEP 12. Check combination meter connector C-04 for loose, corroded or damaged terminals, or terminals pushed back in the connector. 

    Q: Is combination meter connector C-04 in good condition? 

    YES:  Go to Step  13.

    NO:  Repair or replace the damaged component(s). Refer to HARNESS CONNECTOR INSPECTION . Verify that the combination meter works normally.

    Fig 21: Identifying Connector C-04 Terminals

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13. STEP 13. Check the wiring harness between combination meter and the fuel level sensor (sub) for short to ground. Measure the resistance at combination meter connector C-04. 
    1. Disconnect combination meter connector C-04 and fuel level sensor (sub) connector D-10, and measure the resistance available at the harness side of the combination meter connector C-04.
       Fig 22: Identifying Connector C-04 Terminals

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       Fig 23: Locating Fuel Level Sensor Connector D-10 (Eclipse)

       Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
       Fig 24: Locating Fuel Level Sensor Connector D-10 (Eclipse Spyder)

       Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    2. Measure the resistance between combination meter connector C-04 terminal 16 and ground.
       • The resistance should be 1 kΩ or more.

    Q: Is the measured resistance 1 kΩ or more? 

    YES:  Go to Step  15.

    NO:  Go to Step  14.

    Fig 25: Measuring Resistance Between Combination Meter Connector C-04 Terminal 16 And Ground

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14. STEP 14. Check the wiring harness between combination meter connector C-04 (terminal 16) and fuel level sensor (sub) connector D-10 (terminal 2). 
    Fig 26: Identifying Connector C-04 Terminals

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    Fig 27: Locating Fuel Level Sensor Connector D-10 (Eclipse)

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    Fig 28: Locating Fuel Level Sensor Connector D-10 (Eclipse Spyder)

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
    NOTE: Also check intermediate connector C-23 for loose, corroded, or damaged terminals, or terminals pushed back in the connector. If intermediate connector C-23 is damaged, repair or replace the damaged component(s) as described in HARNESS CONNECTOR INSPECTION .

    Q: Is the wiring harness between combination meter connector C-04 (terminal 16) and fuel level sensor connector D-10 (terminal 2) in good condition? 

    YES:  An intermittent malfunction is suspected. Refer to "How to Use Troubleshooting/inspection Service Points - HOW TO COPE WITH INTERMITTENT MALFUNCTIONS " .

    NO:  The wiring harness may be damaged or the connector may have loose, corroded or damaged terminals, or terminals pushed back in the connector. Repair the wiring harness as necessary. Verify that combination meter works normally.

    Fig 29: Identifying Connector C-23 Terminals

    Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
15. STEP 15. Retest the system. 

    Check to see that the fuel gauge operates normally.

    Q: Is the check result satisfactory? 

    YES:  An intermittent malfunction is suspected. Refer to "How to Use Troubleshooting/inspection Service Points - HOW TO COPE WITH INTERMITTENT MALFUNCTIONS " .

    NO:  Replace the combination meter.