Test B: Incorrect Fuel Gauge Indication
- Turn ignition ON. With NGS tester connected, select instrument cluster FUEL LEVEL active command. Scroll to zero, 50 and 100 percent. If fuel gauge displays below empty at zero percent, half full at 50 percent and full at 100 percent, go to next step. If fuel gauge does not display as indicated, replace instrument cluster. See INSTRUMENT CLUSTER under REMOVAL & INSTALLATION.
- Turn ignition switch to LOCK position. Disconnect fuel pump module harness connector C732. Using Instrument Gauge System Tester (014-R1063), connect one lead of tester to fuel pump module harness connector C732 terminal No. 4 (Brown/Red wire) and the other lead to fuel pump module harness connector C732 terminal No. 2 (White/Red wire). Set the tester to 15 ohms, turn ignition switch to ON position and wait approximately one minute. Turn ignition switch to LOCK position. Set the tester to 160 ohms, turn the ignition switch to ON position and wait approximately one minute. The fuel gauge should read EMPTY when the tester is set to 15 ohms and FULL when the test is set to 160 ohms. If fuel gauge operates as specified, go to next step. If fuel gauge does not operate as specified, go to step 5.
- Inspect fuel tank for damage or deformations. If no damage is found, go to next step. If any damage is found, replace fuel tank and test system operation. See FUEL TANK under FUEL SYSTEM in REMOVAL, OVERHAUL & INSTALLATION article in ENGINE PERFORMANCE.
- Inspect fuel pump module wiring and connectors for damage. If no damage is found, replace fuel level sensor and test system operation. If any damage is found, repair or replace as necessary and test system operation.
- Turn ignition switch to LOCK position. Disconnect instrument cluster connector C809. See Figure. Disconnect fuel pump module connector C732. See Fig 1. Measure resistance between terminal No. 8 (White/Red wire) at instrument cluster harness connector and terminal No. 2 (White/Red wire) at fuel pump module harness connector. Measure resistance between ground and terminal No. 8 (White/Red wire) at instrument cluster harness connector. Measure resistance between terminal No. 15 (Brown/Red wire) at instrument cluster harness connector and terminal No. 4 (Brown/Red wire) at fuel pump module harness connector. Measure resistance between ground and terminal No. 15 (Brown/Red wire) at instrument cluster harness connector.
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, replace instrument cluster. 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 open or short to ground in White/Red wire or Brown/Red wire and retest.