Test C: Incorrect Fuel Gauge Indication
NOTE:
Fuel gauge indication will require at least 10 minutes to update if fuel tank has less than 2.5 gallons.
- Turn ignition switch to LOCK position. Connect New Generation Star (NGS) tester to Data Link Connector (DLC). DLC is located below driver's side of instrument panel, right of steering column. Turn ignition switch to RUN position. Using NGS tester, select instrument cluster active command FUELLEVEL. Trigger, monitor and scroll FUELLEVEL at 0%, 50% and 100%. Fuel gauge should indicate empty at 0%, half at 50% and full at 100%. If fuel gauge responds as specified, go to next step. If fuel gauge does not respond as specified, go to step 8 .
- Turn ignition switch to LOCK position. Disconnect Black fuel pump module harness connector C420. Fuel pump module harness connector C420 is located at underside of luggage compartment. Using Gauge System Tester (014-R1063), connect one lead to fuel pump module harness connector C420 terminal No. 5 (Yellow/White wire) and the second lead to terminal No. 8 (Black/Orange wire). See Fig 1 . Set gauge system tester to 160 ohms. Turn gauge system tester on. Turn ignition switch to RUN position, wait one second. Turn ignition switch to LOCK position. Set gauge system tester to 15 ohms. Turn ignition switch to RUN position, wait one minute. Fuel gauge should read empty or below. Turn ignition switch to LOCK position. Set gauge system tester to 160 ohms. Turn ignition switch to RUN position, wait one minute. Fuel gauge should read full or above. Turn ignition switch to OFF position. If fuel gauge operates as specified, go to next step. If fuel gauge did not operate as specified, go to step 5 .
- Visually inspect fuel tank for damage or deformation. If no damage exists, go to next step. If damage exists, replace fuel tank.
- Remove fuel pump module. Inspect fuel pump module for damaged wiring or connectors. Check float and float rod for damage or obstruction. If problem exists, repair as necessary. If problem does not exist, replace fuel pump module.
- Disconnect 20-pin instrument cluster harness connector C251. It may be necessary to remove instrument cluster for access to connector. See REMOVAL & INSTALLATION . Turn ignition switch to RUN position. Measure voltage between ground and instrument cluster harness connector C251 terminal No. 19 (Yellow/White wire). See Figure . If voltage does not exist, go to next step. If any voltage exists, repair short to voltage in Yellow/White wire between instrument cluster and fuel pump module. See WIRING DIAGRAMS .
- Measure resistance in Yellow/White wire between fuel pump module harness connector C420 terminal No. 5 and instrument cluster harness connector C251 terminal No. 19. See Fig 1 . Resistance should be 5 ohms or less. Measure resistance between ground and instrument cluster harness connector C251 terminal No. 19 (Yellow/White wire). Resistance should be more than 10 k/ohms. If both resistances readings are as specified, go to next step. If either resistance reading is not as specified, repair open or short to ground in Yellow/White wire between instrument cluster and fuel pump module. See WIRING DIAGRAMS .
- Measure resistance between ground and fuel pump module harness connector C420 terminal No. 8 (Black/Orange wire). Measure resistance between ground and instrument cluster harness connector C251 terminal No. 20 (Black/White wire). If both resistance readings are 5 ohms or less, go to next step. If either resistance reading is more than 5 ohms, repair open in appropriate wire between ground and instrument cluster or fuel pump module. Ground point is located behind center of instrument panel. See WIRING DIAGRAMS .
- Disconnect all instrument cluster harness connectors. Inspect all instrument cluster harness connectors for loose, damaged or corroded terminals. If terminals are damaged, repair as necessary. If terminals are not damaged, reconnect all instrument cluster harness connectors. Ensure instrument cluster harness connectors are seated properly. If problem still exists, replace instrument cluster module. See REMOVAL & INSTALLATION .