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Test D: Incorrect Fuel Gauge Indication

NOTE: Fuel gauge does not change indication unless there has been at least 3 gallons of fuel added or deleted between ignition cycles.
  1. Using NGS tester, perform Rear Electronic Module (REM) and instrument cluster self-tests. If no DTCs were retrieved, go to next step. If any DTCs were retrieved, go to step  6.
  2. Turn ignition switch to ON position. Using NGS tester, select IC FUEL GAUGE CONTROL active command. Trigger FUELLEVEL active command. Monitor fuel gauge while adjusting FUELLEVEL active command to read 50% and 100%. If fuel gauge needle started at empty (E), moved to half at 50% and then moved to full (F) at 100%, go to next step. If fuel gauge needle does not started at empty (E), moved to half at 50% and then moved to full (F) at 100%, replace instrument cluster.
  3. Turn ignition switch to OFF position. Disconnect fuel pump module 8-pin harness connector C412, located at top of fuel tank. Connect one lead of Instrument Gauge System Tester (014-R1063) or equivalent to fuel pump module harness connector C412 terminal No. 5 (Light Blue/Yellow wire). Connect second lead from Instrument Gauge System Tester (IGST) to fuel pump module harness connector C412 terminal No. 8 (Light Green/Violet wire). Turn IGST power switch to ON position and set IGST to 15 ohms. Turn ignition switch to ON position, wait one minute. Turn ignition switch to OFF position. Set IGST to 160 ohms. Turn ignition switch to ON position, wait one minute. Fuel gauge should read full or above. Turn ignition switch to OFF position. Set IGST to 15 ohms. Turn ignition switch to ON position, wait one minute. Fuel gauge should read empty or below. Turn ignition switch to OFF position. If fuel gauge operated correctly, go to next step. If fuel gauge does not operate correctly, go to step  6.
  4. Visually inspect fuel tank for damage or deformation. If there is no damage or deformity, go to next step. If there is damage or deformity, replace fuel tank.
  5. Inspect fuel pump assembly for damaged wiring, connectors, float and float rod or obstruction. If fuel pump or wiring is damaged, repair as necessary. If fuel pump and wiring are okay, replace fuel level sender.
  6. Disconnect Rear Electronic Module (REM) harness connectors. Measure resistance between REM harness connector C343 terminal No. 15 (Light Green/Violet wire) and ground. Measure resistance between REM harness connector C342 terminal No. 23 (Light Blue/Yellow wire) and ground. If resistance is less than 10 k/ohms at both terminals, go to next step. If resistance is 10 k/ohms or more at both terminals, go to step  8.
  7. Disconnect fuel pump module 8-pin harness connector C412. Measure resistance between REM harness connector C343 terminal No. 15 (Light Green/Violet wire) and ground. Measure resistance between REM harness connector C342 terminal No. 23 (Light Blue/Yellow wire) and ground. If resistance is less than 10 k/ohms at either terminal, repair short to ground in Light Green/Violet wire or Light Blue/Yellow wire. If resistance is 10 k/ohms or more at both terminals, repair fuel sender circuit.
  8. Turn ignition switch to OFF position. Disconnect REM harness connectors. Disconnect fuel pump module 8-pin harness connector C412. Measure resistance in Light Green/Violet wire between REM harness connector C343 terminal No. 15 and fuel pump module harness connector C412 terminal No. 8. Measure resistance in Light Blue/Yellow wire between REM harness connector C342 terminal No. 23 and fuel pump module harness connector C412 terminal No. 5. If both resistances are less than 5 ohms, go to next step. If either resistance is 5 ohms or more, repair open in Light Green/Violet wire and/or Light Blue/Yellow wire.
  9. Measure resistance between fuel pump module terminals No. 5 and 8 (component side). If resistance is 15-160 ohms, go to next step. If resistance is not 15-160 ohms, repair or replace fuel pump module as necessary.
  10. Turn ignition switch to ON position. Measure voltage between REM harness connector C343 terminal No. 15 (Light Green/Violet wire) and ground. Measure voltage between REM harness connector C342 terminal No. 23 (Light Blue/Yellow wire) and ground. If voltage is not present, go to next step. If voltage is present, repair short to voltage in Light Green/Violet wire and/or Light Blue/Yellow wire.
  11. Measure voltage between ground and fuel pump module harness connector C412 terminals No. 8 (Light Green/Violet wire) and No. 5 (Light Blue/Yellow wire). If voltage is present, repair short to voltage. If voltage is not present, replace REM. Test system for normal operation. If incorrect fuel gauge indication is still present, replace instrument cluster.
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