Fuel Gage Inaccurate or Inoperative Gas
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. |
Test Description
The numbers below refer to the step numbers 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 VCM when you perform this diagnostic table.
Step | Action | Value(s) | Yes | No | ||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|
Schematic Reference: Instrument Cluster: Analog Schematics | ||||||||||||
1 |
Important: Verify the J 33431-C resistance settings with a DMM. Does the fuel gage move from empty to full? | -- | Go to Step 3 | Go to Step 2 | ||||||||
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 Fuel Level parameter move from approximately 0 % to approximately 100 %? | -- | Go to Step 9 | Go to Step 4 | |||||||||
3 | Inspect for the following items:
Did you find and correct the condition? | -- | Go to Step 14 | Go to Step 6 | ||||||||
4 | 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 14 | Go to Step 5 | ||||||||
5 | 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 14 | Go to Step 8 | ||||||||
6 |
Did you find and correct the condition? | -- | Go to Step 14 | Go to Step 7 | ||||||||
7 |
Does the resistance change smoothly across the specified range? | 40-250 ohms | Go to Diagnostic Aids | Go to Step 12 | ||||||||
8 | Inspect for poor connections at the harness connector of the VCM. 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 14 | Go to Step 13 | ||||||||
9 | 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 14 | Go to Step 10 | ||||||||
10 | 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 14 | Go to Step 11 | ||||||||
11 | Replace the IPC. Refer to Instrument Cluster Replacement . Did you complete the replacement? | -- | Go to Step 14 | -- | ||||||||
12 | Replace the fuel level sensor. Refer to the appropriate procedure:
Did you complete the replacement? | -- | Go to Step 14 | -- | ||||||||
13 |
Important: Program the replacement VCM. Replace the VCM. Refer to the appropriate procedure:
Did you complete the replacement? | -- | Go to Step 14 | -- | ||||||||
14 |
Did you correct the condition? | -- | System OK | Go to Step 1 | ||||||||
Fuel Gage Inaccurate or Inoperative Diesel
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. |
Step | Action | Value(s) | Yes | No | ||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|
Schematic Reference: Instrument Cluster: Analog Schematics | ||||||||||||
1 |
Important: Verify the J 33431-C resistance settings with a DMM. Does the fuel gage move from empty to full? | -- | Go to Step 2 | Go to Step 3 | ||||||||
2 | Inspect for the following items:
Did you find and correct the condition? | -- | Go to Step 19 | Go to Step 4 | ||||||||
3 | 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 19 | Go to Step 5 | ||||||||
4 |
Did you find and correct the condition? | -- | Go to Step 19 | Go to Step 10 | ||||||||
5 | 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 19 | Go to Step 6 | ||||||||
6 | 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 19 | Go to Step 7 | ||||||||
7 | 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 8 | Go to Step 11 | ||||||||
8 |
Is the voltage at the specified value? | 5 V | Go to Step 15 | Go to Step 9 | ||||||||
9 | 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 19 | Go to Step 14 | ||||||||
10 |
Does the resistance change smoothly across the specified range? | 40-250ohms | Go to Diagnostic Aids | Go to Step 17 | ||||||||
11 | 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 19 | Go to Step 12 | ||||||||
12 | 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 19 | Go to Step 13 | ||||||||
13 | 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 19 | Go to Step 16 | ||||||||
14 | 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 19 | Go to Step 18 | ||||||||
15 | Replace the fuel sender buffer module. Refer to Fuel Sender Buffer Module Replacement . Did you complete the replacement? | -- | Go to Step 19 | -- | ||||||||
16 | Replace the IPC. Refer to Instrument Cluster Replacement . Did you complete the replacement? | -- | Go to Step 19 | -- | ||||||||
17 | Replace the fuel level sensor. Refer to Fuel Sender Assembly Replacement in Engine Controls - 6.5L. Did you complete the replacement? | -- | Go to Step 19 | -- | ||||||||
18 | Replace the passlock module. Refer to Theft Deterrent Module Replacement in Theft Deterrent. Did you complete the replacement? | -- | Go to Step 19 | -- | ||||||||
19 | Operate the system in order to verify the repair. Did you correct the condition? | -- | System OK | Go to Step 1 | ||||||||
