Diagnosis & Repair Procedure
- If engine system check has been performed, go to next step. If engine system check has not been performed, go to A4: ENGINE SYSTEM CHECK under SYSTEM TESTS.
- If DTC P0463 is set along with this DTC, perform testing for DTC P0463 before proceeding with this test. For diagnostic procedure, go to DTC P0463 . If no other DTCs were set, go to next step.
- If SUZUKI scan tool is available, go to next step. If SUZUKI scan tool is not available, go to step 5.
- Turn ignition on. Using scan tool, select DATA LIST mode and observe and note FUEL LEVEL parameter. Add one gallon (3.7L) of fuel to fuel tank. Recheck fuel level. If fuel level parameter increases on scan tool, problem is probably intermittent. See INTERMITTENTS
in TROUBLE SHOOTING - NO CODES article. If intermittent problem is not found, substitute a known good ECM and retest system. If fuel level parameter does not increase, go to step 6.
- Access ECM. ECM is located under instrument panel, behind glove box. See Figure. Turn ignition on. Backprobing at ECM, measure voltage between ground and ECM connector E61 terminal No. 28 (Blue/White wire). See Figure. Note voltage reading. Turn ignition off. Add one gallon (3.7L) of fuel to fuel tank. Turn ignition on. Measure voltage between ground and ECM connector E61 terminal No. 28 (Blue/White wire). If voltage is now lower, problem is probably intermittent. See INTERMITTENTS
in TROUBLE SHOOTING - NO CODES article. If intermittent problem is not found, substitute a known good ECM and retest system. If voltage is not lower, go to next step.
- Turn ignition off. Disconnect fuel tank level sensor 12-pin in-line harness connector. See Fig 1. Check for poor terminal contact at fuel level sensor in-line harness connector. If problem is found, repair as necessary. After repair, retest system. If terminal contact is okay, go to next step.
- Measure and note resistance between fuel tank level sensor in-line harness connector terminals No. 3 (Black/Yellow wire) and No. 4 (Blue/White wire). See Fig 2. Add one gallon (3.7 L) of fuel is to fuel tank. If resistance decreases smoothly within a 2-130 ohm range, go to step 9. If resistance does not decrease, or resistance is out of range, go to next step.
- Check for open or short in Blue/White wire between fuel level sensor, fuel level gauge and ECM. See WIRING DIAGRAMS
article. Also, check for open or short in Black/Yellow wire between ground and fuel level sensor. If problem is found, repair as necessary. If no problem is found, replace fuel level sensor. After repair, retest system.
- Turn ignition off. Disconnect ECM 35-pin harness connector E61. ECM is located under instrument panel, behind glove box. See Figure. Check for poor terminal contact at ECM harness connector E61. If problem is found, repair as necessary. After repair, retest system. If terminal contact is okay, go to next step.
- Turn ignition on. With fuel level sensor in-line harness connector disconnected, fuel level gauge should indicate empty. Connect a fused jumper wire between ground and harness side of fuel tank level sensor in-line harness connector terminal No. 4 (Blue/White wire). Fuel level gauge should indicate full. If fuel level gauge operates as specified, substitute a known good ECM and retest system. If fuel level gauge does not operate as specified, go to next step.
- Check for open or short in Blue/White wire between fuel level sensor, fuel level gauge and ECM. See WIRING DIAGRAMS
article. If problem is found, repair as necessary. After repair, retest system. If no problem with wiring is found, replace fuel level gauge. After repair, retest system.
Courtesy of SUZUKI OF AMERICA CORP.
Courtesy of SUZUKI OF AMERICA CORP.