Schematic Reference: Instrument Cluster Schematics

Connector End View Reference: Master Electrical Component List

1

Did you perform the Diagnostic System Check - Vehicle?

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Go to Step 2

Go to Diagnostic System Check - Vehicle

1. Disconnect C101.
2. 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 female terminal side of the connector.
3. Turn the ignition ON, with the engine OFF.

Important: Verify the J 33431-C resistance settings with a DMM.

4. Vary the resistance on the J 33431-C from 40-250 ohms.
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?

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Go to Step 4

Go to Step 3

3

1. Install a scan tool.
2. Turn the ignition ON, with the engine OFF.

Important: Verify the J 33431-C resistance settings with a DMM.

3. Vary the resistance on the J 33431-C from 40-250 ohms.
4. Refer to Fuel Level Specifications in order to convert from resistance to fuel level percent.

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 evaporative emission (EVAP) Data, data list

•	Fuel Level Sensor parameter in the PCM EVAP Data, data list for the 4.2L only

Does the scan tool indicate that the Fuel Tank Level Remaining or the Fuel Level Sensor parameter is less than the specified value?

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Go to Step 11

Go to Step 5

Inspect for the following items:

Did you find and correct the condition?

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Go to Step 13

Go to Step 7

Test the signal circuit of the fuel level sensor for a high resistance. Refer to Circuit Testing and Wiring Repairs .

Did you find and correct the condition?

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Go to Step 13

Go to Step 6

Test the low reference circuit of the fuel level sensor for a high resistance. Refer to Circuit Testing and Wiring Repairs .

Did you find and correct the condition?

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Go to Step 13

Go to Step 9

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 (ice)

Did you find and correct the condition?

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Go to Step 13

Go to Step 8

1. With the DMM, measure the resistance of the fuel level sensor 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 ohms

Go to Diagnostic Aids

Go to Step 10

Inspect for poor connections at the harness connector of the PCM. Refer to Testing for Intermittent Conditions and Poor Connections .

Did you find and correct the condition?

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Go to Step 13

Go to Step 12

Replace the fuel level sensor. Refer to the following:

Did you complete the replacement?

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Go to Step 13

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Replace the instrument panel cluster (IPC). Refer to Control Module References for replacement, setup, and programming.

Did you complete the replacement?

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Go to Step 13

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Replace the PCM. Refer to Control Module References for replacement, setup, and programming.

Did you complete the replacement?

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Go to Step 13

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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?

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System OK

Go to Step 2