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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 battery voltage is present and fuse is okay, go to next step. If battery voltage does not exist, repair short to ground in Purple wire and retest vehicle.
  2. Partially remove instrument cluster. Ensure cluster connectors are properly installed. Measure voltage at cluster connector C2, pin No. 5 (Purple wire). If battery voltage exists at C2, pin No. 5 (Purple wire), go to next step. If battery voltage does not exist, repair Purple wire for open circuit and retest. See Figure & 4.
  3. Using an ohmmeter, measure resistance between instrument cluster connector C2, pin No. 4 (Black/Yellow wire) and ground. Measure resistance between instrument cluster connector C1, pin No. 13 (Black wire) and ground. See Figure and Figure . If resistance is less than 5 ohms, go to next step. If resistance is more than 5 ohms, repair open Black/Yellow or Black wire.
  4. With ignition switch in OFF position, disconnect fuel pump module harness connector under rear seat. Using Instrument Gauge System Tester (014-R1063), connect tester to harness side of connector pin No. 5, (White/Red wire) and pin No. 4, (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, (White/Red wire) and ground. If resistance is less than 10 k/ohms, repair White/Red wire for short to ground and retest. If resistance is more than 10 k/ohms, replace fuel gauge. Check gauge operation. 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 open White/Red wire and check gauge operation.
  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 open Black wire and check gauge operation.
  9. Disconnect fuel pump module connector. Check resistance between fuel pump module harness connector pin No. 4 (Black/Blue wire) and ground. If resistance is less than 5 ohms, replace fuel gauge. Check gauge operation. If resistance is more than 5 ohms, repair open Black/Blue wire for open and check gauge operation.
  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 pins No. 5 (White/Red wire) and No. 4 (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 in full position, check resistance between fuel pump module pins No. 5 (White/Red wire) and No. 4 (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 as in previous step, slowly move float rod from full stop to empty stop. If ohmmeter reading slowly decreases, repair open White/Red wire for open circuit and retest. If ohmmeter reading does not respond, replace fuel pump module and retest.
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