Test B: Incorrect Fuel Gauge Indication (Without Flex Fuel)
NOTE:
Perform all voltage and resistance tests using an 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. Disconnect fuel pump module 4-pin harness connector C434, located at center rear, under car. See Figure. Connect instrument gauge system tester (014-R1063) to fuel pump module harness connector C434 terminal No. 3 (Black/Yellow wire) and No. 2 (Yellow/White wire). See Fig 1. See WIRING DIAGRAMS . Set tester to 160 ohms. Turn ignition switch to RUN position. Turn tester power switch to ON position and wait for one minute. Fuel gauge should read FULL or above. Turn ignition switch to LOCK position. Set tester to 15 ohms. Turn ignition switch to RUN position and wait for one minute. Fuel gauge should read EMPTY or below. Turn ignition switch to LOCK position. If fuel gauge reads correctly, go to next step. If fuel gauge does not read correctly, go to step 4.
- Inspect fuel tank for any damage or deformation. If fuel tank is okay, go to next step. If fuel tank is faulty, replace fuel tank. See FUEL GAUGE SENDING UNIT under REMOVAL & INSTALLATION. After repair, test system for normal operation.
- Remove fuel pump assembly from fuel tank. SeeFUEL GAUGE SENDING UNIT under REMOVAL & INSTALLATION. Inspect fuel pump assembly for damage to wiring or connectors. Inspect float and float rod for damage or obstruction. If fuel pump and wiring are okay, replace fuel level sensor. If fuel pump or wiring is faulty, repair as necessary. After repair, test system for normal operation.
- Measure resistance between ground and fuel pump module harness connector C434 terminal No. 3 (Black/Yellow wire). See Fig 1. See WIRING DIAGRAMS . If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open circuit in Black/Yellow wire between fuel pump module and ground point located behind center of instrument cluster. SeeFigure. After repair, test system for normal operation.
- Turn ignition switch to LOCK position. Disconnect instrument cluster 16-pin harness connectors C220a, located behind instrument cluster. See Figure. It may be necessary to remove instrument cluster to access connectors. See INSTRUMENT CLUSTER under REMOVAL & INSTALLATION. Measure resistance between instrument cluster harness connector C220a terminal No. 7 and fuel pump module harness connector C434 terminal No. 2 (Yellow/White wire). See Figure and Fig 1 . Also measure resistance between ground and instrument cluster harness connector C220a terminal No. 7 (Yellow/White wire). See WIRING DIAGRAMS . Resistance should be less than 5 ohms at measurement between instrument cluster and fuel pump module, and more than 10 k/ohms at measurement between ground and instrument cluster. If resistances are as specified, go to next step. If any resistance is not as specified, repair open or short circuit in Yellow/White wire between instrument cluster and fuel pump module. After repair, test system for normal operation.
- Inspect instrument cluster printed circuit for contamination or damage. If instrument cluster printed circuit is okay, replace fuel gauge and fuel gauge indicator module. See FUEL GAUGE/TEMPERATURE GAUGE under REMOVAL & INSTALLATION. If instrument cluster printed circuit is faulty, replace instrument cluster printed circuit. See PRINTED CIRCUIT under REMOVAL & INSTALLATION. After repair, test system for normal operation.