Test C: Fuel Gauge Inaccurate (Except Flex Fuel Vehicle)

Turn ignition switch to LOCK position. Disconnect fuel pump/fuel gauge sender harness connector C496. Connect Instrument Gauge System Tester (014-R1063) to Yellow/White wire terminal at fuel pump/fuel gauge sender harness connector C496. Set tester to 15 ohms. Turn ignition switch to RUN position, wait 60 seconds. Fuel gauge should read empty or below. Turn ignition switch to LOCK position. Set tester to 160 ohms. Turn ignition switch to RUN position, wait 60 seconds. Fuel gauge should read full or above. If fuel does not respond as specified, go to next step. If fuel gauge responds as specified, go to step 4 .
Remove fuel tank from vehicle. Inspect fuel tank for damage. If fuel tank is okay, go to next step. If fuel tank is damaged, repair or replace fuel tank as necessary.
Inspect fuel pump/fuel gauge sender assembly. Inspect fuel pump/fuel gauge sender wiring. If problem exists, repair as necessary. If problem does not exist, replace fuel level sender.
Turn ignition switch to LOCK position. Disconnect negative battery cable. Measure resistance in Yellow/White wire between fuel pump/fuel gauge sender harness connector C496 and terminal No. 7 at instrument cluster harness connector C250. See Figure . Resistance should be 5 ohms or less. Also, measure resistance between ground and terminal No. 7 (Yellow/White wire) at instrument cluster harness connector C250. Resistance should be greater than 10 k/ohms. If both resistance readings are as specified, go to next step. If either resistance reading is not as specified, repair open and/or short to ground in Yellow/White wire.
Measure resistance between ground and Black/Yellow wire terminal at fuel pump/fuel gauge sender harness connector C496. If resistance is 5 ohms or less, go to next step. If resistance is greater than 5 ohms, repair open in Black/Yellow wire.

Disconnect negative battery cable. Disconnect instrument cluster harness connectors C250 and C251. Check continuity of instrument cluster printed circuit between terminals of printed circuit flex connection and terminals at gauge. See FUEL GAUGE CONTINUITY table. If there is continuity for each circuit, replace instrument cluster gauge amplifier and fuel gauge/temperature gauge. If there is no continuity, replace instrument cluster printed circuit.

FUEL GAUGE CONTINUITY

Terminal No.	Gauge Terminal
C250-10	B +
C250-8	GND
C250-7	SIG