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 Testing for Intermittent Conditions and Poor Connections in Wiring Systems.

• | Refer to Fuel Level Specifications in order to verify the correct fuel level sensor readings. The Fuel Level parameter is available on the scan tool in the Powertrain Fuel and Emissions data list.

### Test Description

The numbers below refer to the step number on the diagnostic table.

1. This step tests for a high resistance in the signal circuit and the low reference circuit of the fuel level sensor.

2. DTCs will be set in the ECM/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 | Go to Diagnostic System Check - Instrument Cluster
2 |

1. Disconnect C406.
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 female 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?

--

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

5. With the scan tool, observe the Fuel Level parameter in the Powertrain Fuel and Emissions data list.

Does the Fuel Level parameter display the correct fuel level?

--

Go to Step 11

Go to Step 5

4 | Inspect for the following items:

• | A poor connection at the harness connector of the fuel level sensor

| Refer to Testing for Intermittent Conditions and Poor Connections and to Connector Repairs in Wiring Systems.

• | A high resistance in the signal circuit or the low reference circuit between the fuel level sensor and C406

• | A misaligned fuel level sender

• | A deformed fuel tank

Did you find and correct the condition?

--

Go to Step 13

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 13 | 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 13 | Go to Step 9
7 |

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?

--

Go to Step 13

Go to Step 8

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

9 | Inspect for poor connections at the harness connector of the ECM/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 13 | Go to Step 12
10 | Replace the fuel level sensor. Refer to Fuel Level Sensor Replacement in Engine Controls - 2.2L or to Fuel Level Sensor Replacement in Engine Controls - 3.0L. Did you complete the replacement? | -- | Go to Step 13 | --
11 | Replace the IPC. Refer to Instrument Cluster Replacement . Did you complete the replacement? | -- | Go to Step 13 | --
12 | Important: Program the replacement ECM/PCM. Replace the ECM/PCM. Refer to Engine Control Module Replacement in Engine Controls - 3.0L or to Powertrain Control Module Replacement in Engine Controls - 2.2L. Did you complete the replacement? | -- | Go to Step 13 | --
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?

--

System OK

Go to Step 2