For 1990-2009 cars

Step | Action | Value(s) | Yes | No
--- | --- | --- | --- | ---
1 | Did you perform Instrument Cluster System Check? | -- | Go to Step 2 | Go to Instrument Cluster System Check
2 |

1. Turn the ignition switch to LOCK.
2. Disconnect the powertrain control module (PCM) connector C1.
3. Disconnect the fuel level sensor.
4. Connect the red lead of the J 33431-C to fuel level sensor connector cavity 2.
5. Connect the other lead to ground.
6. Set the resistance dial on the tester to 120 ohms, 32 ohms, and 3 ohms.

Does the fuel gauge indicate the appropriate reading at the specified resistance values?

E at 120 ohms

Half tank at 32 ohms

F at 3 ohms

Go to Step 3

Go to Step 6

3 | Test for an open in the BLK wire between the fuel level sensor and G400 using a J 39200 . Does an open exist? | -- | Go to Step 4 | Go to Step 5
4 | Repair the open in the BLK wire between the fuel level sensor and G400. Refer to Wiring Repairs in Wiring Systems. Is the repair complete? | -- | Go to Instrument Cluster System Check | --
5 | Replace the fuel level sensor. Is the repair complete? | -- | Go to Instrument Cluster System Check | --
6 |

1. Disconnect the J 33431-C .
2. Disconnect the instrument panel cluster assembly connector C3.
3. Use a J 39200 digital multimeter in order to probe the instrument panel cluster assembly connector C3 from terminal 9 to the fuel level sensor connector cavity 2.
4. Measure the resistance.

Is the resistance greater than the specified value?

5.0 ohms

Go to Step 7

Go to Step 8

7 | Repair the open in the YEL/RED wire between the instrument panel cluster assembly and the fuel level sensor. Refer to Wiring Repairs in Wiring Systems. Is the repair complete? | -- | Go to Instrument Cluster System Check | --
8 | Inspect for high resistance in the instrument panel cluster printed circuit. Does high resistance exist? | -- | Go to Step 9 | Go to Step 10
9 | Repair the instrument panel cluster printed circuit. Is the repair complete? | -- | Go to Instrument Cluster System Check | --
10 | Replace the fuel gauge. If the problem persists, refer to Driveability and Emissions in Engine Controls in order to diagnose the PCM (fuel level sensor circuit). Is the repair complete? | -- | Go to Instrument Cluster System Check | --