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Fuel Gauge Inaccurate (Vehicles Without Flex Fuel)

  1. Turn ignition switch to OFF position. Disconnect rear lamp wiring harness connector from main wiring harness connector. Connect Instrument Gauge System Tester (014-R1063) to circuit No. 29 (Yellow/White wire) at main wiring harness. Set tester to 22 ohms. Turn ignition switch to run position, wait 60 seconds and read fuel gauge. If fuel gauge reads empty and low fuel warning light is on, go to step 4). If gauge does not read empty, leave tester connected and go to next step.
  2. Turn ignition switch to OFF position. Disconnect negative battery cable. Remove instrument cluster. See INSTRUMENT CLUSTER  under REMOVAL & INSTALLATION. Test continuity between instrument cluster connector C250, pin No. 8 (Black/Yellow wire) and ground. See Figure . If continuity exists, go to next step. If no continuity exists, repair open in circuit No. 398 (Black/Yellow wire) between main wiring harness connector and cluster connector C250. Retest system.
  3. Disconnect instrument cluster connector C250. Test continuity between instrument cluster connector C250, pin No. 7 (Yellow/White wire) and fuel pump/gauge connector. See Figure . If continuity exists, go to step 5). If no continuity exists, repair open in circuit No. 29 (Yellow/White wire) between instrument cluster connector C250 and fuel pump/gauge connector.
  4. Disconnect negative battery cable. Remove instrument cluster. See INSTRUMENT CLUSTER  under REMOVAL & INSTALLATION. Disconnect instrument cluster connectors C250 and C251. Check continuity of instrument cluster printed circuit between terminals of printed circuit flex connection and terminals at gauge. Refer to the FUEL GAUGE CONTINUITY  table. If there is continuity for each circuit, replace instrument cluster gauge amplifier and fuel gauge/temperature gauge. Retest system. If there is no continuity, replace instrument cluster printed circuit and retest system.
    FUEL GAUGE CONTINUITY

    Flex Connector-Pin No. Gauge Terminal
    C250-10 B+
    C250-1 GND
    C250-8 SIG
  5. Connect negative battery cable. Set tester to 145 ohms. Turn ignition switch to RUN position, wait 60 seconds and read fuel gauge. If fuel gauge reads full and low fuel light is off, go to next step. If gauge does not read full, repeat step 4).
  6. Remove fuel tank from vehicle. See FUEL GAUGE SENDING UNIT  under REMOVAL & INSTALLATION. Remove fuel pump module from tank. Inspect fuel tank for distortion or damage. If fuel tank is okay, go to next step. If fuel tank is distorted or damaged, replace fuel tank and go to next step.
  7. Inspect fuel pump module, float and float rod for damage. If fuel pump, float and float rod are okay, go to next step. If not okay, replace fuel pump module and retest system.
  8. Check resistance of circuit No. 29 (Yellow/White wire) between fuel pump module connector and rear light wiring connector. If resistance is less than 5 ohms, go to next step. If resistance is more than 5 ohms, repair open in circuit No. 29 (Yellow/White wire) and retest system.
  9. Check resistance of circuit No. 398 (Black/Yellow wire) between fuel pump module connector and ground. If resistance is less than 5 ohms, replace fuel pump module and retest system. If resistance is more than 5 ohms, repair open in circuit No. 398 (Black/Yellow wire) and retest.
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