Test C: Incorrect Fuel Gauge Indication
CAUTION:
Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.
NOTE:
Fuel gauge indication will require at least 10 minutes to update if fuel tank has less than 2.5 gallons.
NOTE:
Perform all voltage and resistance tests using a Digital Volt-Ohm Meter (DVOM) with a minimum 10-megohm input impedance, unless stated otherwise in test procedure. Use ohmmeter to isolate wiring harness shorts or opens.
- Turn ignition switch to LOCK position. Connect Worldwide Diagnostic System (WDS) tester or New Generation Star (NGS) tester to Data Link Connector (DLC). See Figure. DLC is located under instrument panel between steering column and the radio. See Figure. Turn ignition switch to RUN position. Using WDS or 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 fuel pump module 8-pin harness connector C463. See Fig 1. Fuel pump module harness connector C463 is located at underside of luggage compartment. See Figure. Using Gauge System Tester (014-R1063) or equivalent, connect one lead to fuel pump module harness connector C463 terminal No. 5 (Black/Orange wire) and the second lead to terminal No. 8 (Yellow/White wire). Set gauge system tester to 160 ohms. 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 (E) 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 (F) full or above. Turn ignition switch to LOCK 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. After repair, clear DTCs, repeat self-test and check system for normal operation.
- 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 or replace as necessary. If problem does not exist, replace fuel pump module. See FUEL PUMP MODULE under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION article in ENGINE PERFORMANCE.
- Disconnect 20-pin instrument cluster harness connector C220b. See Figure. It may be necessary to remove instrument cluster for access to connector. See INSTRUMENT CLUSTER MODULE under REMOVAL & INSTALLATION. Turn ignition switch to RUN position. Measure voltage between ground and instrument cluster harness connector C220b terminal No. 19 (Yellow/White wire). If voltage does not exist, go to next step. If any voltage exists, repair short circuit in Yellow/White wire between instrument cluster and fuel pump module. For INSTRUMENT CLUSTER circuit identification, see WIRING DIAGRAMS . After repair, test system for normal operation.
- Turn ignition to switch to LOCK position. Measure resistance between fuel pump module harness connector C463 terminal No. 8 and instrument cluster harness connector C220b terminal No. 19 (Yellow/White wire). See Fig 1 and Figure . Resistance should be 5 ohms or less. Also measure resistance between ground and instrument cluster harness connector C220b 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 circuit in Yellow/White wire between instrument cluster and fuel pump module. For INSTRUMENT CLUSTER circuit identification, see WIRING DIAGRAMS . After repair, test system for normal operation.
- Measure resistance between ground and fuel pump module harness connector C463 terminal No. 5 (Black/Orange wire). Measure resistance between ground and instrument cluster harness connector C220b 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 circuit in appropriate wire between ground point G204 and instrument cluster or fuel pump module. Ground point G204 is located behind center of instrument panel. See Figure. For INSTRUMENT CLUSTER circuit identification, see WIRING DIAGRAMS . After repair, test system for normal operation.
- Disconnect all instrument cluster harness connectors. Inspect all instrument cluster harness connectors for loose, damaged or corroded terminals. If terminals are damaged, repair or replace 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 INSTRUMENT CLUSTER MODULE under REMOVAL & INSTALLATION. After repair, clear DTCs, repeat self-test and check system for normal operation.