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Test I: Fuel Gauge Inaccurate/Inoperative: Testing

  1. If instrument panel cluster diagnostic system check has been performed, go to next step. If instrument panel cluster diagnostic system check has not been performed, go to INSTRUMENT PANEL CLUSTER DIAGNOSTIC SYSTEM CHECK  under SELF-DIAGNOSTIC SYSTEM.
  2. Disconnect in-line 16-pin harness connector C305C. In-line harness connector C305 is located as pass through under vehicle behind driver's seat, and includes three separate connectors on female side. Connect Signal Generator and Instrument Panel Tester (J33431-C) between in-line harness connector C305 terminals 3B and 3D (male terminal side). See Figure. Turn ignition switch to RUN position. Connect DVOM to signal generator and instrument panel tester. Vary resistance on signal generator and instrument panel tester between 40-250 ohms comparing reading to fuel level specifications table. See FUEL LEVEL SPECIFICATIONS  table. If fuel gauge displays incorrect readings, go to next step. If fuel gauge displays correct readings, go to step  4.
    FUEL LEVEL SPECIFICATIONS

    Fuel Gauge Display Ohms Fuel Level Percentage
    E 40-55 2-13%
    1/4 90 31%
    1/2 132 55%
    3/4 164 74%
    F 205-250 93-100%
    Low Fuel Indicator On 56 14%
  3. Turn ignition switch to OFF position. Connect scan tool to Data Link Connector (DLC). DLC is located under left side of instrument panel. Turn ignition switch to RUN position. Using scan tool, observe Fuel Level percentage parameter in Powertrain Control Module (PCM) EVAP data list. Vary resistance on signal generator and instrument panel tester between 40-250 ohms comparing reading to fuel level specifications table. See FUEL LEVEL SPECIFICATIONS  table. To quickly update scan tool display, turn ignition switch to OFF position momentarily between resistance settings. If scan tool displays correct fuel level percentage, go to step  11. If scan tool does not display correct fuel level percentage, go to step  5.
  4. Check for poor, loose or corroded terminals at fuel level sensor harness connector. Check for high resistance in fuel level sender signal or low reference circuit between fuel sender and in-line harness connector C305. See WIRING DIAGRAMS . Check for binding or misaligned fuel level sensor. Check for damage to fuel tank. If problem exists, repair as necessary and go to step  13. If no problem exists, go to step  7.
  5. Check for high resistance in fuel level sensor signal circuit, Purple wire between PCM harness connector C1 terminal No. 69 and fuel level sensor harness connector terminal "A". See Figure and Figure . If no problem exists, go to next step. If problem exists, repair as necessary and go to step  13.
  6. Check for high resistance in fuel level sensor low reference circuit, Black wire between PCM harness connector C2 terminal No. 35 and fuel level sensor harness connector terminal "D". If problem exists, repair as necessary and go to step  13. If no problem exists, go to step  9.
  7. Remove fuel level sensor. Fuel level sensor is located in fuel tank. Check for stuck fuel level sensor and/or strainer interfering with fuel level sensor arm. Check for foreign material in fuel tank. If no problem exists, go to next step. If problem exists, repair as necessary and go to step  13.
  8. Using DVOM connected to fuel level sensor harness connector terminals "A" and "D", component side, measure resistance of fuel level sensor while moving float arm up and down. Resistance should change smoothly from 40-250 ohms as arm is moved. If resistance changes smoothly while moving arm, go to DIAGNOSTIC AIDS . If resistance does not change smoothly while moving arm, go to step  10.
  9. Check for poor, loose or corroded terminals in PCM harness connector C1. If problem exists, repair as necessary and go to step  13. If no problem exists, go to step  12.
  10. Replace the fuel level sensor. See appropriate REMOVAL, OVERHAUL and INSTALLATION article in ENGINE PERFORMANCE. After repairs are made, go to step  13.
  11. Replace IPC. See INSTRUMENT PANEL CLUSTER  under REMOVAL & INSTALLATION. After repairs are made, go to step  13.
  12. Replace the PCM. See POWERTRAIN CONTROL MODULE under REMOVAL & INSTALLATION in BODY CONTROL MODULES - AZTEK article. After repairs are made, go to next step.
  13. Using scan tool, clear DTCs. Operate vehicle through drive cycle. Check system for normal operation. If system operates normally, test is complete. If system does not operate normally, go to step  2.
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