Diagnosis & Repair Procedure
- Check for DTCs. See RETRIEVING DIAGNOSTIC TROUBLE CODES
under SELF-DIAGNOSTIC SYSTEM. If DTC P0463 is set, test that DTC first. See DTC P0463: FUEL LEVEL SENSOR CIRCUIT HIGH VOLTAGE INPUT
. If DTC P0463 is not set, go to next step.
- If not using scan tool, go to next step. If using scan tool, turn ignition off. Connect scan tool. Turn ignition on. Check fuel level on scan tool. Add one gallon (3.7L) of fuel to fuel tank. Recheck fuel level. If fuel level increases on scan tool, problem is intermittent. System is okay at this time. See TROUBLE SHOOTING - NO CODES article. If intermittent problem is not found, replace ECM. Retest system. If fuel level does not increase, go to step 4
.
- Turn ignition on. Backprobing, measure voltage between ground and ECM 26-pin connector E91 terminal No. 8 (Pink/Blue wire). See Figure
. Turn ignition off. Add one gallon (3.7L) of fuel to fuel tank. Turn ignition on. Measure voltage between ground and ECM 26-pin connector E91 terminal No. 8 (Pink/Blue wire). If voltage is now lower, problem is intermittent. System is okay at this time. See TROUBLE SHOOTING - NO CODES article. If intermittent problem is not found, replace ECM. Retest system. If voltage is not lower, go to next step.
- Turn ignition off. Disconnect fuel level sensor harness connector. See Fig 1
. Check for poor terminal contact at fuel level sensor connector. If poor terminal contact is found, repair as necessary. If terminal contact is okay, measure resistance between component side of fuel level sensor harness connector terminals No. 2 (Black wire) and No. 4 (Pink/Blue wire) as one gallon (3.7 L) of fuel is added to fuel tank. See Fig 2
. See WIRING DIAGRAMS article. Go to next step.
- If resistance decreases smoothly within a 3-120 ohm range, go to next step. If resistance does not decrease, or resistance is out of range, check for short or open in Pink/Blue wire between fuel level sensor, fuel gauge and ECM 26-pin connector E91 terminal No. 8. See Figure
. If wire is okay, replace fuel level sensor. Retest system.
- Disconnect ECM 26-pin connectors E91. Check for good terminal contact at ECM 26-pin connector E91. If poor terminal contact is found, repair as necessary. If terminal contact is okay, turn ignition on. With fuel level sensor disconnected, fuel gauge should indicate empty. Connect a fused jumper wire between harness side of fuel level sensor harness connector terminals No. 2 (Black wire) and No. 4 (Pink/Blue wire). Go to next step.
- Fuel gauge should indicate full. If fuel gauge operates as specified, replace ECM. Retest system. If fuel gauge does not operate as specified, check for short or open in Pink/Blue wire between fuel level sensor, fuel gauge and ECM 26-pin connector E91. See WIRING DIAGRAMS article. Also check for open in Black wire between fuel level sensor and ground. If wires are okay, replace fuel gauge. Retest system.
Courtesy of SUZUKI OF AMERICA CORP.
Courtesy of SUZUKI OF AMERICA CORP.