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Fuel Gauge Inoperative

  1. Set ignition switch to ON position. Observe other gauges and indicators. If other gauges operate normally, cluster is receiving battery voltage, and grounds are good. If other gauges do not operate normally, go to step 5). If testing fuel gauge with resistors, go to step 2). If testing fuel gauge with substitute fuel tank sending unit, go to step 4).
  2. Unplug harness connector from fuel tank sending unit. Connect 145-ohm resistor (or Rotunda Gauge System Tester 021-00055 set to 145 ohms) between harness connector Yellow/White wire terminal and ground. Turn ignition on. Fuel gauge should indicate at or above FULL mark.
  3. Connect 22-ohm resistor (or tester set to 22 ohms) between harness connector Yellow/White wire terminal and ground. Turn ignition on. Fuel gauge should indicate at or below EMPTY mark. If gauge does not respond as indicated, check for open or short circuit in wiring or replace gauge as necessary. If gauge functions as indicated, replace sending unit.
  4. Unplug connector from sending unit. Connect it to substitute sending unit. Ensure sending unit is grounded. Move sending unit float to FULL position (away from filter). Turn ignition on. Gauge should indicate at or above FULL mark. Turn ignition off. Move sending unit float to EMPTY position (toward fuel filter). Wait about 30 seconds, and then turn ignition on. Fuel gauge should indicate at or below EMPTY mark. If gauge does not respond as specified, check for open or short circuit in wiring or replace gauge as necessary. If gauge functions as specified, replace sending unit.
  5. Ensure battery voltage is present at warning indicator fuse. Partially remove instrument cluster to ensure cluster harness connections are secure. See INSTRUMENT CLUSTER R & I  under REMOVAL & INSTALLATION. Using DVOM, ensure battery voltage is present at cluster connector by backprobing battery terminal (Red/Yellow wire). Using DVOM, check cluster ground circuit continuity. Repair as necessary.
  6. Ensure ignition switch is in OFF position. Unplug fuel gauge sending unit connector. Use Rotunda Gauge System Tester 021-00055, or use resistors as in step 2). If using tester, install tester in cluster side of harness connector Yellow/White wire and set to 22 ohms. If using resistors, connect 22-ohm resistor between cluster side of harness connector Yellow/White wire and ground.
  7. Set ignition switch to RUN position, wait 60 seconds, then read fuel gauge. Fuel gauge should indicate EMPTY. If gauge does not indicate EMPTY, turn ignition off. Remove instrument cluster. Inspect printed circuit for open fuel gauge circuit. If circuit is okay, remove anti-slosh module from rear of cluster.
  8. Remove tester (or resistor) from harness connector. Using jumper wire, connect tester (or 22-ohm resistor) directly to fuel gauge "S" terminal on rear of cluster. Reconnect instrument cluster to harness. Set ignition switch to RUN position. If fuel gauge now indicates EMPTY, replace anti-slosh module. If fuel gauge does not indicate EMPTY, replace fuel gauge.
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