Fuel Gage Inaccurate or Inoperative Single Tank 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. |
| • | The Fuel Tank Level Remaining (%) parameter is available on the scan tool in the VCM Enhanced Evap data list. Use the fuel sender resistance (40-250 ohms) to verify the fuel sender operation. When the fuel tank is empty, the sender is 40 ohms and when the fuel tank is full the sender resistance is 250 0hms. |
Step | Action | Value(s) | Yes | No | ||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|
1 | Did you perform the Instrument Cluster Diagnostic System Check? | -- | Go to Step 2 | |||||||||
2 |
Important:: Verify the J 33431-C resistance settings with a DMM. The fuel gauge should indicate empty at 40 ohms and full at 250 ohms. Does the fuel gauge display the correct fuel level? | -- | Go to Step 4 | Go to Step 3 | ||||||||
3 |
Important:: Verify the J 33431-C resistance settings with a DMM. The fuel gauge should indicate empty at 40 ohms and full at 250 ohms. Important:: Turn OFF the ignition momentarily between the resistance settings in order to quickly update the scan tool display. Does the scan tool display the correct fuel level %? | -- | Go to Step 5 | Go to Step 6 | ||||||||
4 | Inspect for the following items:
Did you find and correct the condition? | -- | Go to Step 15 | Go to Step 8 | ||||||||
5 | Test the fuel level signal circuit for a high resistance between the IPC and the VCM. Refer to Circuit Testing and Wiring Repairs in Wiring Systems. Did you find and correct the condition? | -- | Go to Step 15 | Go to Step 10 | ||||||||
6 | Test the signal circuit of the fuel level sender for a high resistance between C130 and the VCM. Refer to Circuit Testing and Wiring Repairs in Wiring Systems. Did you find and correct the condition? | -- | Go to Step 15 | Go to Step 7 | ||||||||
7 | Test the low reference circuit of the fuel level sender for a high resistance between C130 and the VCM. Refer to Circuit Testing and Wiring Repairs in Wiring Systems. Did you find and correct the condition? | -- | Go to Step 15 | Go to Step 11 | ||||||||
8 |
Did you find and correct the condition? | -- | Go to Step 15 | Go to Step 9 | ||||||||
9 |
Does the resistance change smoothly across the specified range? | 40-250 ohms | Go to Diagnostic Aids | Go to Step 12 | ||||||||
10 | Inspect for poor connections at the harness connector of the IPC. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs in Wiring Systems. Did you find and correct the condition? | -- | Go to Step 15 | Go to Step 13 | ||||||||
11 | Inspect for poor connections at the harness connector of the VCM. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs in Wiring Systems. Did you find and correct the condition? | -- | Go to Step 15 | Go to Step 14 | ||||||||
12 | Replace the fuel level sender. Refer to Fuel Level Sensor Replacement in Engine Controls - 5.0 L and 5.7 L or Fuel Level Sensor Replacement in Engine Controls - 7.4 L. Did you complete the replacement? | -- | Go to Step 15 | -- | ||||||||
13 | Replace the IPC. Refer to Instrument Cluster Replacement . Did you complete the replacement? | -- | Go to Step 15 | -- | ||||||||
14 |
Important: Program the replacement VCM. Replace the VCM. Refer to VCM Replacement/Programming in Engine Controls - 5.0 L and 5.7 L or VCM Replacement/Programming in Engine Controls - 7.4 L. Did you complete the replacement? | -- | Go to Step 15 | -- | ||||||||
15 |
Did you correct the condition? | -- | System OK | Go to Step 2 |
Fuel Gage Inaccurate or Inoperative Single Tank Diesel L65
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. |
| • | Use the fuel sender resistance (0-90 ohms) to verify the fuel level sender operation. When the fuel tank is empty the sender resistance is 0 ohms and when the fuel tank is full the sender resistance is 90 ohms. |
Step | Action | Value(s) | Yes | No | ||||||
|---|---|---|---|---|---|---|---|---|---|---|
1 | Did you perform the Instrument Cluster Diagnostic System Check? | -- | Go to Step 2 | |||||||
2 |
Important:: Verify the J 33431-C resistance settings with a DMM. The fuel gauge should indicate empty at 0 ohms and full at 90 ohms. Does the fuel gauge display the correct fuel level? | -- | Go to Step 3 | Go to Step 4 | ||||||
3 | Test the signal circuit of the fuel level sender for an open, a short to ground or a high resistance between C104 and the fuel level sensor. Refer to Circuit Testing and Wiring Repairs in Wiring Systems. Did you find and correct the condition? | -- | Go to Step 12 | Go to Step 6 | ||||||
4 | Test the signal circuit of the fuel level sender for an open, a short to ground or a high resistance between C104 and the IPC. Refer to Circuit Testing and Wiring Repairs in Wiring Systems. Did you find and correct the condition? | -- | Go to Step 12 | Go to Step 5 | ||||||
5 | Test the fuel sender ground circuit for an open or a high resistance. Refer to Circuit Testing and Wiring Repairs in Wiring Systems. Did you find and correct the condition? | -- | Go to Step 12 | Go to Step 9 | ||||||
6 | Inspect for the following items:
Did you find and correct the condition? | -- | Go to Step 12 | Go to Step 7 | ||||||
7 |
Did you find and correct the condition? | Go to Step 12 | Go to Step 8 | |||||||
8 |
Does the resistance change smoothly across the specified range? | 0-90 ohms | Go to Diagnostic Aids | Go to Step 10 | ||||||
9 | Inspect for poor connections at the harness connector of the IPC. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs in Wiring Systems. Did you find and correct the condition? | -- | Go to Step 12 | Go to Step 11 | ||||||
10 | Replace the fuel level sender. Refer to Fuel Sender Assembly Replacement in Engine Controls - 6.5L (L65). Did you complete the replacement? | -- | Go to Step 12 | -- | ||||||
11 | Replace the IPC. Refer to Instrument Cluster Replacement . Did you complete the replacement? | -- | Go to Step 12 | -- | ||||||
12 | Operate the system in order to verify the repair. Did you correct the condition? | -- | System OK | Go to Step 2 |
Fuel Gage Inaccurate or Inoperative Dual Tank Gas
Diagnostic Aids
| • | Verify 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 . |
| • | Use the fuel level sensor resistance in order to verify the fuel level sensor operation. When the fuel tank is empty, the fuel level sensor resistance is approximately 40 ohms. When the fuel tank is full the fuel level sensor resistance is approximately 250 ohms. |
Test Description
The number below refers to the step number on the diagnostic table.
Step | Action | Value(s) | Yes | No | ||||||
|---|---|---|---|---|---|---|---|---|---|---|
1 | Did you perform the Instrument Cluster Diagnostic System Check? | -- | Go to Step 2 | |||||||
2 |
Important: Verify the J 33431-C resistance settings with a DMM. Does the fuel gage move from empty to full? | -- | Go to Step 4 | Go to Step 3 | ||||||
3 |
Important: Verify the J 33431-C resistance settings with a DMM. Does the fuel gage move off of empty? | -- | Go to Step 6 | Go to Step 5 | ||||||
4 | Inspect for the following items:
Did you find and correct the condition? | -- | Go to Step 22 | Go to Step 8 | ||||||
5 |
Important: Verify the J 33431-C resistance settings with a DMM. Does the fuel gage move from empty to full? | -- | Go to Step 10 | Go to Step 14 | ||||||
6 | Test the signal circuits of the primary and the secondary fuel level sensors for an open, for a short to ground, 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 22 | Go to Step 7 | ||||||
7 | Test the ground circuits of the primary and the secondary fuel level sensors 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 22 | Go to Step 11 | ||||||
8 |
Did you find and correct the condition? | -- | Go to Step 22 | Go to Step 9 | ||||||
9 |
Does the resistance for both fuel level sensors change smoothly across the specified range? | 40-250 ohms | Go to Diagnostic Aids | Go to Step 18 | ||||||
10 | Test the 5 volt reference circuit for an open, for a short to ground, 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 22 | Go to Step 13 | ||||||
11 | Test the ground circuit of the fuel tank pump balance 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 22 | Go to Step 12 | ||||||
12 | Test the Ignition 1 circuit for an open, a short to ground, 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 22 | Go to Step 16 | ||||||
13 | Test the fuel level signal circuit for an open, for a short to ground, or for a high resistance between the fuel tank pump balance module and the VCM. Refer to Circuit Testing and to Wiring Repairs in Wiring Systems. Did you find and correct the condition? | -- | Go to Step 22 | Go to Step 17 | ||||||
14 | Test the fuel level signal circuit of the IPC for an open, for a short to ground, or for a high resistance between the VCM and the IPC. Refer to Circuit Testing and to Wiring Repairs in Wiring Systems. Did you find and correct the condition? | -- | Go to Step 22 | Go to Step 15 | ||||||
15 | 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 22 | Go to Step 19 | ||||||
16 | Inspect for poor connections at the harness connector of the fuel tank pump balance 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 22 | Go to Step 20 | ||||||
17 | Inspect for poor connections at the harness 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 22 | Go to Step 21 | ||||||
18 | Replace the fuel level sensor that did not have the correct resistance values. Refer to the appropriate procedure:
Did you complete the replacement? | -- | Go to Step 22 | -- | ||||||
19 | Replace the IPC. Refer to Instrument Cluster Replacement . Did you complete the replacement? | -- | Go to Step 22 | -- | ||||||
20 | Replace the fuel tank pump balance module. Refer to the appropriate procedure:
Did you complete the replacement? | -- | Go to Step 22 | -- | ||||||
21 |
Important:: Program the replacement VCM. Replace the VCM. Refer to the appropriate procedure:
Did you complete the replacement? | -- | Go to Step 22 | -- | ||||||
Did you correct the condition? | -- | System OK | Go to Step 2 |
Fuel Gage Inaccurate or Inoperative Dual Tank Diesel L65
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. |
| • | Use the fuel sender resistance (0-90 ohms) to verify the fuel sender operation. When the fuel tank is empty, the sender resistance is 0 ohm and when the fuel tank is full the sender resistance is 90 ohms. |
Step | Action | Value(s) | Yes | No | ||||||
|---|---|---|---|---|---|---|---|---|---|---|
1 | Did you perform the Instrument Cluster Diagnostic System Check? | -- | Go to Step 2 | |||||||
2 |
Important: Verify the J 33431-C resistance settings with a DMM. Does the fuel gauge display the correct fuel level? | -- | Go to Step 4 | Go to Step 3 | ||||||
3 |
Important: Verify the J 33431-C resistance settings with a DMM. Does the fuel gauge display the correct fuel level? | -- | Go to Step 6 | Go to Step 5 | ||||||
4 | Inspect for the following items:
Did you find and correct the condition? | -- | Go to Step 16 | Go to Step 9 | ||||||
5 | Test the fuel level signal circuit for an open, a short to ground or a high resistance between the IPC and the fuel balance module. Refer to Circuit Testing and Wiring Repairs in Wiring Systems. Did you find and correct the condition? | -- | Go to Step 16 | Go to Step 8 | ||||||
6 | Test the signal circuits of the fuel level senders for an open, a short to ground or a high resistance between the fuel level senders and the fuel balance module. Refer to Circuit Testing and Wiring Repairs in Wiring Systems. Did you find and correct the condition? | -- | Go to Step 16 | Go to Step 7 | ||||||
7 | Test the ground circuits of the fuel level senders for an open or a high resistance. Refer to Circuit Testing and Wiring Repairs in Wiring Systems. Did you find and correct the condition? | -- | Go to Step 16 | Go to Step 11 | ||||||
8 | Test the ground circuit of the fuel balance module for an open or a high resistance. Refer to Circuit Testing and Wiring Repairs in Wiring Systems. Did you find and correct the condition? | -- | Go to Step 16 | Go to Step 12 | ||||||
9 |
Did you find and correct the condition? | -- | Go to Step 16 | Go to Step 10 | ||||||
10 |
Does the resistance change smoothly across the specified range? | 0-90 ohms | Go to Diagnostic Aids | Go to Step 13 | ||||||
11 | Inspect for poor connections at the harness connector of the fuel balance module. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs in Wiring Systems. Did you find and correct the condition? | -- | Go to Step 16 | Go to Step 15 | ||||||
12 | Inspect for poor connections at the harness connector of the IPC. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs in Wiring Systems. Did you find and correct the condition? | -- | Go to Step 16 | Go to Step 14 | ||||||
13 | Replace the primary or the secondary fuel level sender. Refer to Fuel Sender Assembly Replacement in Engine Controls- 6.5L (L65). Did you complete the replacement? | -- | Go to Step 16 | -- | ||||||
14 | Replace the IPC. Refer to Instrument Cluster Replacement . Did you complete the replacement? | -- | Go to Step 16 | -- | ||||||
15 | Replace the fuel balance module - 6.5 L (L65). Did you complete the replacement? | -- | Go to Step 16 | -- | ||||||
16 | Operate the system in order to verify the repair. Did you correct the condition? | -- | System OK | Go to Step 2 |
