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Fuel Level Sensor: 3.5L

  1. Check instrument cluster operation. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. Repair as necessary. If instrument cluster and circuits are okay, go to next step.
  2. Turn ignition off. Disconnect fuel level sensor harness connector. Connect Signal Generator/Instrument Panel Tester (J-33431-B) to fuel level sensor signal circuit (Purple wire) and fuel level sensor ground circuit (Black/White wire) of fuel level sensor harness connector. Set signal generator tester resistance to 40 ohms. Turn ignition on. Using scan tool, clear any DTCs. Using scan tool, observe fuel level display. Slow turn signal generator tester dial until resistance reaches 248 ohms. If fuel level steadily increases from zero percent to 100 percent, go to next step. If fuel level does not increase as specified, go to step  4.
  3. Turn ignition off. Set signal generator tester resistance to 40 ohms. Turn ignition on. Using scan tool, clear any DTCs. Observe fuel level gauge on instrument cluster. Slow turn signal generator tester dial until resistance reaches 248 ohms. If fuel level steadily increases from empty to full, go to step  5. If fuel level does not increase as specified, repair fuel gauge. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT.
  4. Turn ignition off. Disconnect PCM harness connector C2. Check for poor connections at fuel level sensor and PCM. Check for high resistance in fuel level sensor signal circuit (Purple wire) and fuel level sensor ground circuit (Black/White wire). Using DVOM, check for continuity between fuel level sensor signal circuit (Purple wire) and chassis ground. Continuity should not exist. Using DVOM, check for continuity between fuel level sensor signal circuit (Purple wire) and all other circuits in PCM harness connector and fuel tank connector. Continuity should not exist. If problem exists, repair as necessary. If problem does not exist, go to step  7.
  5. Check for poor connection at fuel level sensor. If problem exists, repair as necessary. If problem does not exist, go to next step.
  6. Replace fuel level sensor.
  7. Replace PCM.
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