Schematic Reference: Instrument Cluster Schematics

1

Did you perform the IPC Diagnostic System Check?

--

Go to Step 2

Go to Diagnostic System Check - Instrument Cluster

1. Disconnect C305.
2. Connect the J 33431-C Signal Generator and Instrument Panel Tester between the signal circuit of the fuel level sensor and the sensor ground circuit of the fuel level sensor (male terminal side).
3. Turn ON the ignition, 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. 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 a scan tool.
2. Turn ON the ignition, 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. Refer to Fuel Level Specifications in order to convert from resistance to fuel level %.

Important: Turn OFF the ignition momentarily between the resistance settings in order to quickly update the scan tool display.

4. With the scan tool, observe the Fuel Level % parameter in the PCM EVAP data list.

Does the scan tool display the correct fuel level %?

--

Go to Step 11

Go to Step 5

Inspect for the following items:

Did you find and correct the condition?

--

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 in Wiring Systems.

Did you find and correct the condition?

--

Go to Step 13

Go to Step 6

Test the sensor ground 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

1. Remove the fuel level sensor.
2. Inspect for the following items:

•	A stuck fuel level sensor (i.e. the fuel strainer interfering with the sensor float arm)

•	Foreign material in the gas tank (ice)

Did you find and correct the condition?

--

Go to Step 13

Go to Step 8

1. With the J 39200 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 and Connector Repairs in Wiring Systems.

Did you find and correct the condition?

--

Go to Step 13

Go to Step 12

Replace the fuel level sensor. Refer to Fuel Level Sensor Replacement in Engine Controls-3.4L.

Did you complete the replacement?

--

Go to Step 13

--

Important: Perform the setup procedure for the replacement IPC.

Replace the IPC. Refer to Instrument Cluster Replacement .

Did you complete the replacement?

--

Go to Step 13

--

Important: Perform the programming procedure for the replacement PCM.

Replace the PCM. Refer to Powertrain Control Module Replacement in Engine Controls-3.4L.

Did you complete the replacement?

--

Go to Step 13

--

13

1. Use a 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