Diesel Data: Automotive Repair

Fuel Level Sensor Circuit







WHEN MONITORED
With the ignition on.

SET CONDITION
Fuel Level Sensor circuit failure between the Fuel Level Sensor and the Instrument Cluster.

POSSIBLE CAUSES
- Fuel level sensor circuit(s) open
- Fuel level sensor
- Instrument cluster

Diagnostic Test




1. MEASURE FUEL LEVEL SENSOR CIRCUIT VOLTAGE

Turn the ignition off.
Disconnect the Fuel Level Sensor harness connector.

NOTE: Check connectors - Clean/repair as necessary. Turn the ignition on.

Measure the voltage between cavity 1 and cavity 2 of the Fuel Level Sensor harness connector.

Q: Is the voltage approximately .7 of a volt?

YES: Replace the Fuel Level Sensor. Perform BODY VERIFICATION TEST. Body Verification Test
NO: Go to 2




2. MEASURE FUEL LEVEL SENSOR CIRCUIT RESISTANCE

Turn the ignition off. Disconnect the Instrument Cluster C2 harness connector.

NOTE: Check connectors - Clean/repair as necessary.

Connect a jumper wire between cavity 1 and cavity 2 of the Fuel Level Sensor harness connector.
Measure the resistance of the Fuel Level Sensor circuit from cavity D4 to cavity D5 at the Instrument Cluster C2 harness connector.

Q: Is the resistance below 5.0 ohms?

YES: Replace the Instrument Cluster. Perform BODY VERIFICATION TEST. Body Verification Test
NO: Repair the appropriate Fuel Level Sensor circuit for an open. Perform BODY VERIFICATION TEST. Body Verification Test