245 ohms

FULL

195 ohms

145 ohms

1/2

97 ohms

42 ohms

EMPTY

Schematic Reference: DTC P0656 Fuel Level Output Circuit

1

Did you perform the Instrument Cluster Diagnostic System Check?

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Go to Step 2

Go to Instrument Cluster System Check

1. Disconnect the fuel level sensor through the access panel in the trunk.
2. Connect the J 33431-C 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. (female side)
3. Turn ON the ignition, with the engine OFF.

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

4. Vary the resistance on the J 33431-C from 42-245 ohms.

Does the fuel gauge move from empty to full?

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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 J 33431-C resistance settings with a DMM.

3. Vary the resistance on the J 33431-C from 42-245 ohms.

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

4. With the scan tool, observe the Fuel Level % parameter in the PCM EVAP data list.

Does the fuel level percent move from approximately 0 % to approximately 100 %?

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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 (ice).

Did you find and correct the condition?

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Go to Step 13

Go to Step 8

1. With the J 39200 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?

42-245 ohms

Go to Diagnostic Aids

Go to Step 10

Inspect for poor connections at the harness connector of the 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 Level Sensor Replacement (3.1L) in Engine Controls.

Did you complete the replacement?

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Go to Step 13

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Replace the IPC. Refer to Instrument Cluster Replacement .

Did you complete the replacement?

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Go to Step 13

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Important: Program the replacement PCM.

Replace the PCM. Refer to Powertrain Control Module Replacement/Programming (3.1L) in Engine Controls.

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 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