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Fuel Gauge Reads Inaccurately

  1. With a voltmeter, verify battery voltage at load side of fuse No. 30. See Figure . If voltage is 10 volts or more at load side of fuse, go to next step. If voltage is less than 10 volts, replace fuse, repair short to ground in circuit No. 14 (Purple wire) and retest vehicle.
  2. Partially remove instrument cluster. Ensure cluster connectors are properly installed. Check for voltage at cluster connector C2, pin No. 5 (Purple wire) and gauge terminal. If there is battery voltage at C2, pin No. 5 (Purple wire) and gauge terminal, go to next step. If no voltage is present, repair circuit No. 14 (Purple wire) for open circuit and retest. See Figure .
  3. With an ohmmeter, check continuity of instrument cluster and gauge ground circuits, cluster connector C2, pin No. 4 (Black/Yellow wire) and connector C1, pin No. 13 (Black wire). See Figure . If resistance is less than 5 ohms, go to next step. If resistance is more than 5 ohms, repair circuits No. 91 (Black/Yellow wire) and No. 31 (Black wire) for open circuit and retest system.
  4. With ignition switch in OFF position, disconnect rear wiring harness connector under rear seat. Using Instrument Gauge System Tester (014-R1063), connect tester to harness side of connector pin No. 5, circuit No. 8 (White/Red wire) and pin No. 4, circuit No. 91 (Black/Yellow wire). Set tester to 145 ohms. Turn ignition switch to RUN position, wait 60 seconds and read fuel gauge. If fuel gauge reads empty, go to next step. If gauge reads other than empty, go to step 6).
  5. Remove instrument cluster. See INSTRUMENT CLUSTER  under REMOVAL & INSTALLATION. Disconnect cluster connector C2. Disconnect fuel pump module connector. Check resistance between fuel pump module signal lead pin No. 5, circuit No. 8 (White/Red wire) and ground. If resistance is less than 10 k/ohms, repair circuit No. 8 (White/Red wire) for short to ground and retest. If resistance is more than 10 k/ohms, replace fuel pump and retest system. See FUEL GAUGE  under REMOVAL & INSTALLATION.
  6. Turn ignition switch to OFF position. Attach Instrument Gauge System Tester (014-R1063) as in step 4). Set tester to 22 ohms. Turn ignition switch to RUN position. Wait 60 seconds and read fuel gauge. If fuel gauge reads full, go to next step. If gauge reads other than full, go to step 10).
  7. Remove instrument cluster. See INSTRUMENT CLUSTER  under REMOVAL & INSTALLATION. Disconnect cluster connector C2. Disconnect fuel pump module connector. Connect ohmmeter between cluster connector C2, pin No. 7 (White/Red wire) and fuel pump module connector pin No. 5 (White/Red wire). If resistance is less than 5 ohms, go to next step. If resistance is more than 5 ohms, repair circuit No. 8 (White/Red wire) for open and retest circuit.
  8. Disconnect cluster connector C1. Check resistance between cluster connector C1, pin No. 13 (Black wire) and ground. If resistance is less than 5 ohms, go to next step. If resistance is more than 5 ohms, repair circuit No. 31 (Black wire) for open and retest.
  9. Disconnect fuel pump module connector. Check resistance between module connector pin No. 4 (Black/Blue wire) and ground. If resistance is less than 5 ohms, replace fuel gauge and retest system. If resistance is more than 5 ohms, repair circuit No. 91 (Black/Yellow wire) for open and retest.
  10. Inspect fuel tank for damage or distortion. If tank has no damage or distortion, go to next step. If tank has damage or distortion, replace tank and retest system.
  11. Remove fuel pump module. See FUEL GAUGE SENDING UNIT  under REMOVAL & INSTALLATION. With float rod against empty stop (closest to filter), check resistance between fuel pump module circuit No. 8 (White/Black wire) and pump module circuit No. 91 (Black/Blue wire). If resistance is 14-18 ohms, go to next step. If resistance is other than 14-18 ohms, replace fuel pump module and retest.
  12. With float rod against full stop, check resistance between fuel pump module signal lead circuit No. 8 (white/Red wire) and module ground circuit No. 91 (Black/Blue wire). If resistance is 145-165 ohms, go to next step. If resistance is other than 145-165 ohms, replace fuel pump module and retest.
  13. With ohmmeter connected between fuel pump module signal lead circuit No. 8 (White/Red wire) and module ground circuit No. 91 (Black/Blue wire), slowly move float rod from full stop to empty stop. If ohmmeter reading slowly decreases, repair circuit No. 8 (White/Red wire) for open circuit and retest. If ohmmeter reading does not respond, replace fuel pump module and retest.
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