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Test TC-149A - Fuel Level Sending Unit Volts Too Low

NOTE: For connector terminal identification, refer to CONNECTOR IDENTIFICATION . For wiring diagram, see WIRING DIAGRAMS article in this section.
  1. Using scan tool, read fuel level sending unit voltage. If voltage is less than 0.2 volt, go to step 5). If voltage is 0.2 volt or more, go to next step.
  2. Wiggle connectors and harness from fuel tank sending unit to PCM and instrument cluster while observing scan tool display. If voltage changes while wiggling, repair connector or harness that caused voltage change and perform TEST VER-2A. If voltage does not change, go to next step.
  3. Condition required to set DTC is not present at this time. FUEL LEVEL SENDING UNIT VOLTAGE TOO LOW DTC sets if Powertrain Control Module (PCM) senses less than 0.2 volt for 2 seconds while ignition is on. Possible causes are: fuel level sensor signal shorted to ground, defective fuel level sending unit, loss of fuel ignition switch output voltage, defective instrument cluster circuit board, defective PCM, defective connector terminals or connector wires. Go to next step.
  4. Inspect all related wiring and connectors. Repair wiring and connectors as necessary and perform TEST VER-2A . If wiring and connectors are okay, test is complete. Perform TEST VER-2A.
  5. Disconnect fuel pump module connector. Inspect connector and terminals for damage. Repair connector and terminals as necessary. If connector and terminals are okay, go to next step.
  6. Using scan tool, read fuel level sending unit voltage. If voltage is more than 4.5 volts, replace fuel pump module and perform TEST VER-2A. If voltage is 4.5 volts or less, go to next step.
  7. Turn ignition off. Disconnect Powertrain Control Module (PCM) connectors. Inspect connectors and terminals for damage. Repair connectors and terminals as necessary and perform TEST VER-2A . If connectors and terminals are okay, go to next step.
  8. Using scan tool in ohmmeter mode, check resistance of PCM Gray connector, fuel level sensor OBD-II signal circuit (Light Blue/Black wire). If resistance is less than 5 ohms, repair short to ground in fuel level sensor OBD-II signal circuit and perform TEST VER-2A. If resistance is 5 ohms or more, go to next step.
  9. Using an external ohmmeter, check resistance between PCM Gray connector, fuel level sensor OBD-II signal circuit (Light Blue/Black wire) and PCM Black connector, sensor ground circuit (Black/Light Blue wire). If resistance is less than 5 ohms, repair fuel level sensor OBD-II signal circuit for a short to sensor ground circuit and perform TEST VER-2A . If resistance is 5 ohms or more, replace PCM and perform TEST VER-2A.
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