Schematic Reference: Instrument Cluster Schematics

Connector End View Reference: Powertrain Control Module Connector End Views in Engine Controls - 2.0L or Engine Control Module Connector End Views in Engine Controls - 2.2L

1

Did you perform the Diagnostic System Check - Vehicle?

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Go to Step 2

Go to Diagnostic System Check - Vehicle in Vehicle DTC Information

1. Disconnect C305.
2. Connect the SA9205Z 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.
3. Turn ON the ignition, with the engine OFF.

Important: Verify the SA9205Z resistance settings with a DMM.

4. Vary the resistance on the SA9205Z 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 ON the ignition, with the engine OFF.

Important: Verify the SA9205Z resistance settings with a DMM.

3. Vary the resistance on the SA9205Z 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 the Fuel Tank Level Remaining parameter in the ECM/PCM EVAP Data List.

Does the Fuel Tank Level Remaining parameter display the correct fuel level percentage?

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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 in Wiring Systems.

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 in Wiring Systems.

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 sensor, 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?

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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 engine control module (ECM)/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?

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Go to Step 13

Go to Step 12

Replace the fuel level sensor. Refer to Fuel Pump Module Replacement in Engine Controls - 2.0L or Fuel Level Sensor Replacement in Engine Controls - 2.2L (L61).

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 in Computer/Integrating Systems for replacement, setup, and programming.

Did you complete the replacement?

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Go to Step 13

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Replace the ECM/PCM. Refer to Control Module References in Computer/Integrating Systems 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 ECM/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