Fuel Gage Inaccurate or Inoperative Gas
Diagnostic Aids
| • | Verify that the fuel level is in the same range as the customer concern. |
| • | For intermittent diagnosis, refer to Testing for Intermittent Conditions and Poor Connections in Wiring Systems. |
| • | Refer to Fuel Level Specifications in order to verify the correct readings for the fuel level sensor. The Fuel Level Remaining parameter is available on the scan tool in the PCM EVAP data list. |
Test Description
The numbers below refer to the step number on the diagnostic table.
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This step tests for a high resistance in the signal circuit and the low reference circuit of the fuel level sensor.
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DTCs will be set in the PCM when you perform this diagnostic table.
Step | Action | Value(s) | Yes | No | ||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
Schematic Reference: Instrument Cluster Schematics | ||||||||||||||||
1 | Did you perform the Instrument Cluster Diagnostic System Check? | -- | Go to Step 2 | |||||||||||||
2 |
Important: Verify the J 33431-C resistance settings with a DMM. Does the fuel gage display the correct fuel level? | -- | Go to Step 4 | Go to Step 3 | ||||||||||||
Important: Verify the J 33431-C resistance settings with a DMM. Important: Turn the ignition OFF momentarily between the resistance settings in order to quickly update the scan tool display. Does the Fuel Tank Level Remaining parameter display the correct fuel level percentage? | -- | Go to Step 10 | Go to Step 5 | |||||||||||||
4 | Inspect for the following items:
Did you find and correct the condition? | -- | Go to Step 15 | Go to Step 7 | ||||||||||||
5 | Test the signal circuit of the fuel level sensor for a high resistance. Refer to Circuit Testing and to Wiring Repairs in Wiring Systems. Did you find and correct the condition? | -- | Go to Step 15 | Go to Step 6 | ||||||||||||
6 | Test the low reference circuit of the fuel level sensor for a high resistance. Refer to Circuit Testing and to Wiring Repairs in Wiring Systems. Did you find and correct the condition? | -- | Go to Step 15 | Go to Step 9 | ||||||||||||
7 |
Did you find and correct the condition? | -- | Go to Step 15 | Go to Step 8 | ||||||||||||
8 |
Does the resistance change smoothly across the specified range? | 40-250 ohms | Go to Diagnostic Aids | Go to Step 13 | ||||||||||||
9 | Inspect for poor connections at the harness connector of the PCM. Refer to Testing for Intermittent Conditions and Poor Connections and to Connector Repairs in Wiring Systems. Did you find and correct the condition? | -- | Go to Step 15 | Go to Step 14 | ||||||||||||
10 | Test the fuel level signal circuit to the IPC for a high resistance. Refer to Circuit Testing and to Wiring Repairs in Wiring Systems. Did you find and correct the condition? | -- | Go to Step 15 | Go to Step 11 | ||||||||||||
11 | Inspect for poor connections at the harness connector of the IPC. Refer to Testing for Intermittent Conditions and Poor Connections and to Connector Repairs in Wiring Systems. Did you find and correct the condition? | -- | Go to Step 15 | Go to Step 12 | ||||||||||||
12 | Replace the IPC. Refer to Instrument Cluster Replacement . Did you complete the replacement? | -- | Go to Step 15 | -- | ||||||||||||
13 | Replace the fuel level sensor. Refer to the appropriate procedure:
Did you complete the replacement? | -- | Go to Step 15 | -- | ||||||||||||
14 |
Important: Program the replacement PCM. Replace the PCM. Refer to the appropriate procedure:
Did you complete the replacement? | -- | Go to Step 15 | -- | ||||||||||||
Did you correct the condition? | -- | System OK | Go to Step 2 | |||||||||||||
Fuel Gage Inaccurate or Inoperative Diesel
Diagnostic Aids
| • | Verify that the fuel level is in the same range as the customer concern. |
| • | For intermittent diagnosis, refer to Testing for Intermittent Conditions and Poor Connections in Wiring Systems. |
| • | Refer to Fuel Level Specifications in order to verify the correct readings for the fuel level sensor. |
Step | Action | Value(s) | Yes | No | ||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
Schematic Reference: Instrument Cluster Schematics | ||||||||||||||||
1 | Did you perform the Instrument Cluster Diagnostic System Check? | -- | Go to Step 2 | |||||||||||||
2 |
Important: Verify the J 33431-C resistance settings with a DMM. Does the fuel gage display the correct fuel level? | -- | Go to Step 3 | Go to Step 4 | ||||||||||||
3 | Inspect for the following items:
Did you find and correct the condition? | -- | Go to Step 20 | Go to Step 5 | ||||||||||||
4 | Test the signal circuit of the fuel level sensor for an open, for a high resistance, or for a short to ground. Refer to Circuit Testing and to Wiring Repairs in Wiring Systems. Did you find and correct the condition? | -- | Go to Step 20 | Go to Step 6 | ||||||||||||
5 |
Did you find and correct the condition? | -- | Go to Step 20 | Go to Step 11 | ||||||||||||
6 | Test the low reference circuit of the fuel level sensor for an open or for a high resistance. Refer to Circuit Testing and to Wiring Repairs in Wiring Systems. Did you find and correct the condition? | -- | Go to Step 20 | Go to Step 7 | ||||||||||||
7 | Test the fuel sender buffer module ignition 1 voltage circuit for an open, for a high resistance, or for a short to ground. Refer to Circuit Testing and to Wiring Repairs in Wiring Systems. Did you find and correct the condition? | -- | Go to Step 20 | Go to Step 8 | ||||||||||||
8 | Using a DMM measure the voltage between the instrument cluster and the fuel sender buffer module. Does the voltage measure greater than the specified value? | 8.0 V | Go to Step 9 | Go to Step 12 | ||||||||||||
9 |
Is the voltage at the specified value? | 5 volts | Go to Step 16 | Go to Step 10 | ||||||||||||
10 | Test the Passlock module 5 volt reference circuit for an open, for a high resistance, or for a short to ground. Refer to Circuit Testing and to Wiring Repairs in Wiring Systems. Did you find and correct the condition? | -- | Go to Step 20 | Go to Step 15 | ||||||||||||
11 |
Does the resistance change smoothly across the specified range? | 40-250 ohms | Go to Diagnostic Aids | Go to Step 18 | ||||||||||||
12 | Test the ground circuit of the fuel sender buffer module for an open or for a high resistance. Refer to Circuit Testing and to Wiring Repairs in Wiring Systems. Did you find and correct the condition? | -- | Go to Step 20 | Go to Step 13 | ||||||||||||
13 | Test the fuel level signal circuit to the instrument cluster for an open, for a high resistance, or for a short to ground. Refer to Circuit Testing and to Wiring Repairs in Wiring Systems. Did you find and correct the condition? | -- | Go to Step 20 | Go to Step 14 | ||||||||||||
14 | Inspect for poor connections at the harness connector of the IPC. Refer to Testing for Intermittent Conditions and Poor Connections and to Connector Repairs in Wiring Systems. Did you find and correct the condition? | -- | Go to Step 20 | Go to Step 17 | ||||||||||||
15 | Inspect for poor connections at the harness connector of the passlock module. Refer to Testing for Intermittent Conditions and Poor Connections and to Connector Repairs in Wiring Systems. Did you find and correct the condition? | -- | Go to Step 20 | Go to Step 19 | ||||||||||||
16 | Replace the fuel sender buffer module. Refer to Fuel Sender Buffer Module Replacement . Did you complete the replacement? | -- | Go to Step 20 | -- | ||||||||||||
17 | Replace the IPC. Refer to Instrument Cluster Replacement . Did you complete the replacement? | -- | Go to Step 20 | -- | ||||||||||||
18 | Replace the fuel level sender. Refer to Fuel Sender Assembly Replacement in Engine Controls - 6.5L. Did you complete the replacement? | -- | Go to Step 20 | -- | ||||||||||||
19 | Replace the passlock module. Refer to Theft Deterrent Module Replacement in Theft Deterrent. Did you complete the replacement? | -- | Go to Step 20 | -- | ||||||||||||
20 | Operate the system in order to verify the repair. Did you correct the condition? | -- | System OK | Go to Step 2 | ||||||||||||
