Test B: Incorrect Fuel Gauge Indication (Without Flex Fuel)
- Turn ignition switch to LOCK position. Disconnect fuel pump module harness connector C434. Connect 1 lead of Instrument Gauge System Tester (014-R1063) to terminal No. 2 (Yellow/White wire) at fuel pump module harness connector C434. Connect other lead to ground. Set tester to 160 ohms. Turn ignition switch to RUN position. Turn tester POWER switch to ON position. Wait 1 minute. Fuel gauge should read FULL or above. Turn ignition switch to LOCK position. Set tester to 15 ohms. Turn ignition switch to RUN position. Wait 1 minute. Fuel gauge should read EMPTY or below. Turn ignition switch to LOCK position. If fuel gauge reads correctly, go to next step. If fuel gauge does not read correctly, go to step 4 .
- Inspect fuel tank for any damage or deformation. If fuel tank is okay, go to next step. If fuel tank is not okay, replace fuel tank.
- Inspect fuel pump assembly for damage to wiring or connectors. Inspect float and float rod for damage or obstruction. If fuel pump and wiring is okay, replace fuel level sensor. If fuel pump or wiring is not okay, repair as necessary.
- Measure resistance between ground and terminal No. 3 (Black/Yellow wire) at fuel pump module harness connector C434. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Black/Yellow wire and retest.
- Turn ignition switch to LOCK position. Disconnect instrument cluster harness connector C220a. See Figure . Measure resistance between terminal No. 7 (Yellow/White wire) at instrument cluster harness connector C220a and terminal No. 2 (Yellow/White wire) at fuel pump module harness connector C434. Measure resistance between ground and terminal No. 7 (Yellow/White wire) at instrument cluster harness connector C220a. If resistance is less than 5 ohms between instrument cluster and fuel pump module and more than 10 k/ohms between instrument cluster and ground, go to next step. If resistance is more than 5 ohms between instrument cluster and fuel pump module and less than 10 k/ohms between instrument cluster and ground, repair circuit and test system for normal operation.
- Inspect instrument cluster printed circuit for damage. If instrument cluster printed circuit is okay, replace fuel gauge and indicator module. See FUEL GAUGE/TEMPERATURE GAUGE under REMOVAL & INSTALLATION. If instrument cluster printed circuit is not okay, replace instrument cluster printed circuit. See PRINTED CIRCUIT under REMOVAL & INSTALLATION.