Test Description

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

2: Access the fuel level sender through the trunk.
3: This step tests for a high resistance in the signal circuit and the low reference circuit of the fuel level sensor.
13: DTCs are set in the powertrain control module (PCM) when you perform this diagnostic table.

Fuel Gage Inaccurate or Inoperative

Step	Action	Value(s)	Yes	No
Schematic Reference: Instrument Cluster Schematics
1	Did you perform the Diagnostic System Check - Vehicle?	-	Go to Step 2	Go to Diagnostic System Check - Vehicle
2	Disconnect the fuel level sender. Connect the J 33431-C 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. Turn the ignition ON, with the engine OFF. IMPORTANT: Verify the J 33431-C resistance settings with a DMM. Vary the resistance on the J 33431-C from 40-250 ohms. 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 resistance settings with a DMM. Vary the resistance on the signal generator from 40-250 ohms. 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 PCM EVAP Data list. Does the Fuel Tank Level Remaining parameter display the correct fuel level?	-	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 to Connector Repairs in Wiring Systems. 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 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 sensor for a high resistance. 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	Remove the fuel level sender. 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	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 powertrain control module (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 sensor. Refer to Fuel Level Sensor Replacement in Engine Controls. 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	Replace the PCM. Refer to Engine Control Module (ECM) Replacement in Engine Controls. Did you complete the replacement?	-	Go to Step 13	-
13	Use the scan tool in order to clear the PCM DTCs. Operate the system in order to verify the repair. Did you correct the condition?	-	System OK	Go to Step 2