Fuel Level Sensor Open
NOTE:
After making any repairs, perform BODY VERIFICATION TEST
under VERIFICATION TESTS.
Customer complaint will be gauge shows empty at all times. Instrument cluster monitors fuel level sensor resistance. Diagnostic Trouble Code (DTC) is set when resistance is more than 1100 ohms for 18 seconds.
- Turn ignition off. Connect scan tool to Data Link Connector (DLC). DLC is located on bottom of instrument panel, to left of brake pedal. See Figure . Turn ignition on. Using scan tool, clear DTCs. Turn ignition off, then on. After 30 seconds, recheck DTCs. If FUEL LEVEL SENSOR OPEN is displayed, go to next step. If FUEL LEVEL SENSOR OPEN is not displayed, DTC is intermittent. Road test vehicle and recheck. Check for Technical Service Bulletins (TSBs). Check wiring and connectors.
- Disconnect fuel pump module connector. Fuel pump module connector is located on fuel tank. Check connectors and repair as necessary. Check voltage between fuel pump harness connector terminal No. 3 and ground. See Fig 1 . If voltage does not exist, go to next step. If voltage exists, repair short to voltage on wire between fuel pump module and instrument cluster.
- Using a jumper wire, connect fuel pump harness connector terminal No. 3 to ground. Turn ignition on. Using scan tool, select SENSORS and check fuel sender volts. If scan tool displays zero volts, go to next step. If scan tool does not display zero volts, repair open on wire between fuel pump module and instrument cluster.
- Using ohmmeter, check resistance between fuel pump module connector terminal No. 2, ground circuit and ground. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open wire.
- Using ohmmeter, check resistance between fuel pump module (component side) terminals No. 2, fuel level sensor ground circuit and No. 3, fuel level sensor signal circuit. If resistance is more than 1500 ohms, replace fuel level sensor. Fuel level sensor is mounted on fuel pump module. See FUEL PUMP MODULE under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - CARS article in ENGINE PERFORMANCE. If resistance is 1500 ohms or less, replace instrument cluster. See INSTRUMENT CLUSTER under REMOVAL & INSTALLATION in ANALOG INSTRUMENT PANELS article.