Test A: Fuel Gauge Inaccurate
NOTE:
Fuel pump and fuel gauge sending unit are also referred to as fuel tank module.
- Turn ignition switch to LOCK position. Disconnect fuel tank level sensor and pump 8-pin harness connector C311 at fuel tank. Inspect connector for loose, damaged or corroded terminals. Repair connector as necessary. Connect one lead of Instrument Gauge System Tester (014-R1063) to fuel tank level sensor and pump harness connector C311 terminal No. 5 (Yellow/White wire). See Fig 1 . Connect other tester lead to ground. Set tester to 160 ohms. Turn ignition switch to RUN position and wait one minute. Observe fuel gauge. Fuel gauge should read "F" (full) or more. Turn ignition switch to LOCK position. Set tester to 15 ohms. Turn ignition switch to RUN position and wait one minute. Observe fuel gauge. Fuel gauge should read "E" (empty) or less. If fuel gauge readings are as specified, go to next step. If fuel gauge readings are not as specified, go to step 4 .
- Visually inspect fuel tank for any deformation and damage. Replace fuel tank as necessary and recheck system operation. If fuel tank is okay, go to next step.
- Remove fuel gauge sending unit from fuel tank. See FUEL GAUGE SENDING UNIT under REMOVAL & INSTALLATION. Inspect sending unit float and float rod for damage or obstruction. Repair float and/or float rod as necessary. Recheck system operation. If float and float rod are okay, replace sending unit. Recheck system operation.
- Measure resistance between ground and fuel tank level sensor and pump harness connector C311 terminal No. 8 (Black/Yellow wire). If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Black/Yellow wire between fuel tank level sensor and pump harness connector and ground. Recheck system operation.
- Turn ignition switch to LOCK position. Remove instrument cluster. See INSTRUMENT CLUSTER under REMOVAL & INSTALLATION. Measure resistance of Yellow/White wire between fuel tank level sensor and pump harness connector C311 terminal No. 5 and instrument cluster Black 12-pin harness connector C287 terminal No. 12. Measure resistance between ground and instrument cluster harness connector C287 terminal No. 12 (Yellow/White wire). See Fig 1 and Fig 2 . Resistance should be less than 5 ohms between instrument cluster and fuel level sensor and pump harness connector, and more than 10 k/ohms between instrument cluster and ground. If resistance is as specified, go to next step. If resistance is not as specified, repair open in Yellow/White wire between fuel level sensor and pump, PCM, instrument cluster and message center. Recheck system operation.
- Turn ignition switch to LOCK position. Measure resistance of instrument cluster printed circuit between the following:
- Fuel gauge "S" terminal and gauge amplifier terminal No. 3. See Fig 3 . Gauge amplifier is located on top left side of printed circuit board.
- Fuel gauge terminal "G" and instrument cluster printed circuit terminals at Black 12-pin connector terminal No. 2 (component side).
- Fuel gauge terminal "B" and instrument cluster printed circuit terminal at Black 12-pin connector terminal No. 8 (component side).
- Fuel gauge ground terminal and gauge amplifier terminal No. 5.
- Gauge amplifier and instrument cluster printed circuit terminals at Black 12-pin connector terminals No. 2 and 12 and instrument cluster printed circuit terminal at White 10-pin C288 terminal No. 1 (component side) See Fig 4 .
If all resistance readings are less than one ohm, replace fuel gauge and instrument cluster gauge amplifier. See GAUGES under REMOVAL & INSTALLATION. If any resistance reading is one ohm or more, replace instrument cluster printed circuit. See PRINTED CIRCUIT under REMOVAL & INSTALLATION. Recheck system operation.