DTC 1-1-3 Fuel Gauge Sensor Open-Circuit

Conditions for DTC:
Resistance in fuel level sensor is greater than 335 ohms for more than 10 seconds.

Sources of fault:
- Open-circuit in fuel level sensor.
- Open-circuit in fuel level sensor ground lead.
- Signal lead short-circuited to battery supply.
- Open-circuit in fuel level sensor signal lead.
- Fault in test signal from instrument panel.
- Fuel level sensor faulty, resistance too high.
- High contact resistance.

Symptoms:
- Fuel gauge sticks on empty. Check fuel level sensor.
- Fuel gauge reading too low. Check ground lead.
- Intermittent fault when the fuel gauge can sometimes show empty tank, or too little. Check leads and connections.

Checking Fuel Level Sensor:





- Ignition off.
- Expose gauge sender connector. Service and Repair
- Undo fuel level sensor connector C/BB.
- Connect an ohmmeter across fuel level sensor connector C/BB terminals 1 and 2.
- Ohmmeter should read 8 - 330 Ohms.

If reading is correct:
- Check ground lead, see below.

If reading is incorrect:
- Fault in fuel level sensor. Replace fuel level sensor and test.

Checking Ground Lead:





- Ignition off.
- Connect an ohmmeter between cable harness connector C/BB terminal 2 and ground.
- Ohmmeter should read approx. 0 ohm.

If reading is correct:
- Check test signal to fuel level sensor, see below.

If reading is incorrect:
- Check ground from instrument panel, see below.

Checking Ground From Instrument Panel:





- Ignition off.
- Expose instrument panel. (Remove Dash Board Cover) Service and Repair
- Undo instrument panel connectors.
- Connect test box to cable harness connector and check ground points. Connecting Test (Breakout) Box

Test Box On Dashboard/Cable Harness Dashboard:

- Connect test box between instrument panel and cable harness connector.





- Connect an ohmmeter across test box terminals # 4 (# A4) and # 15 (# A15).
- Ohmmeter should read approx. 0 ohm.

If reading is correct:
- Open-circuit in ground lead between cable harness connector C/BB terminal 2 and instrument panel terminal # A4.
- Check ground lead and connections for open-circuit. Checking Cables and Terminals

If reading is incorrect:
- Fault in instrument panel printed circuit board. Replace printed circuit board and test.

Checking Test Signal To Fuel Level Sensor:





- Ignition on.
- Connect a voltmeter across cable harness connector C/BB terminals 1 and 2.
- Voltmeter should read approx. 7 V.

If reading is correct:
- Contact resistance in signal lead between cable harness connector C/BB terminal 1 and instrument panel terminal # A5.
- Check signal lead and connections for contact resistance. Checking Cables and Terminals

If voltmeter reading equals battery voltage:
- Short-circuit to battery supply in signal lead between cable harness connector C/BB terminal 1 and instrument panel terminal # A5.
Check signal lead and connections for short-circuit to battery supply. Checking Cables and Terminals

If voltmeter reads 0 V:
- Check test signal from instrument panel, see below.

Checking Test Signal From Instrument Panel:





- Ignition off.
- Expose instrument panel. (Remove Dash Board Cover) Service and Repair
- Undo instrument panel connectors.
- Connect test box to cable harness connector and check ground points. Connecting Test (Breakout) Box

Test Box On Dashboard/Cable Harness Dashboard:

- Connect test box between instrument panel and cable harness connector.
- Ignition on.





- Connect a voltmeter between # 5 (# A5) and # 4 (# A4) on test box.
- Voltmeter should read approx. 7 V.

If reading is correct:
- Open-circuit in signal lead between instrument panel terminal # A5 and cable harness connector C/BB terminal 1.
Check signal lead and connections for open-circuit. Checking Cables and Terminals

If reading is incorrect:
- Fault in instrument panel printed circuit board. Replace printed circuit board and test.

Checking Ground Lead:





- Ignition off.
- Expose fuel gauge sender connector. Service and Repair
- Undo fuel level sensor connector C/BB.
- Connect an ohmmeter between cable harness connector C/BB terminal 2 and ground.
- Ohmmeter should read approx. 0 Ohm.

If reading is correct:
- Check test signal to fuel level sensor, see below.

If reading is incorrect:
- Check ground from instrument panel, see below

Checking Ground From Instrument Panel:





- Ignition off.
- Expose instrument panel. (Remove Dash Board Cover) Service and Repair
- Undo instrument panel connector.
- Connect test box to cable harness connector and check ground points. Connecting Test (Breakout) Box

Test Box On Dashboard/Cable Harness Dashboard:

- Connect test box between instrument panel and cable harness connector.





- Connect an ohmmeter across # 4 (# A4) and # 15 (# A15) on test box.
- Ohmmeter should read approx. 0 ohm.

If reading is correct:
- Contact resistance in ground lead between cable harness connector C/BB terminal 2 and instrument panel terminal # A4.
- Check ground lead and connections for contact resistance. Checking Cables and Terminals

If reading is incorrect:
- Fault in instrument panel printed circuit board. Replace printed circuit board and test.

Checking Test Signal To Fuel Level Sensor:





- Ignition on.
- Connect a voltmeter across cable harness connector C/BB terminals 1 and 2.
- Voltmeter should read approx. 7 V.

If reading is correct:
- Check fuel level sensor, see below.

If reading is incorrect:
- Check test signal from instrument panel, see below.

Checking Fuel Level Sensor:





- Ignition off.
- Remove fuel level sensor. Service and Repair
- Put fuel level sensor in right position
- Connect an ohmmeter across fuel level sensor connector C/BB terminals 1 and 2.
- Ohmmeter should read 322 - 330 ohms with fuel level sensor the right way round.

If reading is correct:
- Contact resistance in signal lead between instrument panel connector terminal # A5 and cable harness connector C/BB terminal 1.
- Check signal lead and connections for contact resistance. Checking Cables and Terminals

If reading is incorrect:
- Fault in fuel level sensor. Replace fuel level sensor and test.

Checking Test Signal From Instrument Panel:





- Ignition off.
- Expose instrument panel. (Remove Dash Board Cover) Service and Repair
- Undo instrument panel connectors.
- Connect test box to cable harness connector and check ground points. Connecting Test (Breakout) Box

Test Box On Dashboard/Cable Harness Dashboard:

- Connect test box between instrument panel and cable harness connector.
- Ignition on.





- Connect a voltmeter between # 5 (# A5) and # 4 (# A4) on test box.
- Voltmeter should read approx. 7 V.

If reading is correct:
- Contact resistance in signal lead between instrument panel terminal # A5 and cable harness connector C/BB terminal 1.
- Check signal lead and connections for contact resistance. Checking Cables and Terminals

If reading is incorrect:
- Fault in instrument panel printed circuit board. Replace printed circuit board and test.

Checking Fuel Level Sensor Leads and Connections.





- Check fuel sensor and instrument panel connector for intermittent open-circuit, loose contact, contact resistance and oxidization. Checking Cables and Terminals