For 1990-2009 cars

### Diagnostic Aids

• | Ensure that the fuel level is in the same range as the customer concern.

• | For intermittent diagnosis, refer to Intermittents and Poor Connections Diagnosis in Wiring Systems.

### Test Description

The number(s) below refer to the step number(s) in the diagnostic table.

1. This step tests for a high resistance in the signal circuit and the ground circuit of the fuel level sender.

2. DTCs will be set in the PCM when you perform this diagnostic table.

Step | Action | Value(s) | Yes | No
--- | --- | --- | --- | ---
SCHEMATIC REFERENCE: Engine Controls Schematics (2.4L) or Engine Controls Schematics (3.4L) in Engine Controls
1 | Did you perform the Instrument Cluster System Check? | -- | Go to Step 2 | Go to Instrument Cluster System Check
2 |

1. Install a scan tool.
2. Turn ON the ignition, with the engine OFF.
3. Select the PCM display DTCs function on the scan tool.

Does the scan tool display any DTCs?

--

Go to Diagnostic Trouble Code (DTC) List (2.4L) or Diagnostic Trouble Code (DTC) List (3.4L) in Engine Controls

Go to Step 3

3 | With the scan tool, select Instrument Panel Cluster, Special Functions and command the fuel gauge UP. Does the fuel gauge complete a full sweep when commanded? | -- | Go to Step 4 | Go to Step 12
4 |

1. Turn OFF the ignition.
2. Disconnect the fuel level sender.
3. Connect the J 33431-C Signal Generator and Instrument Panel Tester between the signal circuit of the fuel level sender and the ground circuit of the fuel level sender.
4. Turn ON the ignition, with the engine OFF.

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

5. Set the resistance on the J 33431-C to 40 ohms.

Does the fuel gauge display at or below empty?

--

Go to Step 5

Go to Step 6

5 | Inspect for the following items:

• | A poor connection at the harness connector of the fuel level sender. Refer to Intermittents and Poor Connections Diagnosis and Connector Repairs in Wiring Systems.

• | A misaligned fuel level sender.

• | A deformed fuel tank.

Did you find and correct the condition?

--

Go to Step 14

Go to Step 8

6 | Test the signal circuit of the fuel level sender for a high resistance. Refer to Circuit Testing and Wiring Repairs in Wiring Systems. Did you find and correct the condition? | -- | Go to Step 14 | Go to Step 7
7 | Test the ground circuit of the fuel level sender for a high resistance. Refer to Circuit Testing and Wiring Repairs in Wiring Systems. Did you find and correct the condition? | -- | Go to Step 14 | Go to Step 10
8 |

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 gas tank (ice).

Did you find and correct the condition?

--

Go to Step 14

Go to Step 9

9 |

1. With the J 39200 DMM, measure the resistance of the fuel level sender 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 11

10 | Inspect for poor connections at the harness connector of the PCM. Refer to Intermittents and Poor Connections Diagnosis and Connector Repairs in Wiring Systems. Did you find and correct the condition? | -- | Go to Step 14 | Go to Step 13
11 | Replace the fuel level sender. Refer to Fuel Level Sensor Replacement (2.4L) or Fuel Level Sensor Replacement (3.4L) in Engine Controls. Did you complete the replacement? | -- | Go to Step 14 | --
12 | Replace the IPC. Refer to Instrument Cluster Replacement . Did you complete the repair? | -- | Go to Step 14 | --
13 | Important: Program the replacement PCM. Replace the PCM. Refer to Powertrain Control Module Replacement (2.4L) or Powertrain Control Module Replacement/Programming (3.4L) in Engine Controls. Did you complete the replacement? | -- | Go to Step 14 | --
14 |

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?

--

System OK

Go to Step 2