Possible Causes

circuit (Y/W) open or short to ground
circuit (B/W) open
fuel tank
fuel level sensor and pump assembly
instrument cluster
powertrain control module (PCM)
CAUTION:
- Use the correct probe adaptor(s) when making measurements. Failure to use the correct probe adaptor(s) may damage the connector.

INCORRECT FUEL GAUGE INDICATION PINPOINT TEST REFERENCE

PINPOINT TEST 21		INCORRECT FUEL GAUGE INDICATION
STEP	INSPECTION		ACTION
1	CARRY OUT THE INSTRUMENT CLUSTER GAUGES ACTIVE COMMAND USING THE DIAGNOSTIC TOOL NOTE: Turn the ignition switch to the OFF position, remove and reinstall the SJB fuse 33 (5A), turn the ignition switch to the ON position, and check the fuel gauge for proper indication. If the fuel gauge indication is OK, advise the operator not to fill the fuel tank with the ignition switch in the ON or ACC positions. If the fuel gauge indication is not OK, proceed with the following pinpoint test. Key ON. Enter the following diagnostic mode on the diagnostic tool: Instrument Cluster Active Command. Select the instrument cluster gauges active command. Trigger, monitor, and sweep the gauges. Observe the fuel gauge. Does the fuel gauge sweep correctly?	Yes	Go to next step.
1		No	Go to step 12.
2	RETRIEVE THE RECORDED DIAGNOSTIC TROUBLE CODES (DTCs) FROM BOTH THE CONTINUOUS AND ON-DEMAND INSTRUMENT CLUSTER SELF-TESTS Check the recorded instrument cluster DTCs from the continuous and on-demand self-tests. Are DTCs present?	Yes	Clear the DTCs. Go to next step.
2		No	Go to step 4.
3	CHECK THE INSTRUMENT CLUSTER AND THE FUEL LEVEL SENSOR AND PUMP CONNECTIONS Key OFF. Disconnect: Instrument cluster 0922-101,0922-102. Disconnect: Fuel level sensor and pump 0114-02. Connect: Instrument cluster 0922-101, 0922-102. Connect: Fuel level sensor and pump 0114-02. Key ON. Carry out the instrument cluster self-test. Are any DTCs still present?	Yes	If DTC B1202, go to step 8. If DTC B1204, go to step 9.
3		No	The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector.
47	CHECK THE FUEL GAUGE OPERATION NOTE: Gear Select Procedure: Vehicles equipped with automatic transmissions, apply the brake and move the shift lever from P to D. Wait 10 seconds, move the shift lever back to P. Wait 30 seconds. Vehicles equipped with a manual transmissions, apply the parking brake. Wait 10 seconds, and release the parking brake. Wait 30 seconds. Do not change the ignition switch position until 30 seconds have elapsed. Key Off. NOTE: The fuse must be removed to reset the fuel gauge timers. Failure to complete this step may result in erroneous test result. Remove the smart junction box (SJB) fuse 33 (5A). Wait 1 minute and reinstall the fuse. Disconnect the fuel level sensor and pump 0114-02. Connect one lead of the instrument gauge system tester to the fuel level sensor and pump 0114-02 pin 2, circuit (Y/W), harness side. Connect the other lead to ground. Key On Engine Off (KOEO). Perform gear select procedure. Key Off. Set the tester to 160 ohms. Key On Engine Off (KOEO). Perform gear select procedure. Key Off. Wait 30 seconds. Set the tester to 15 ohms. Key On Engine Off (KOEO). Perform gear select procedure. Observe the fuel gauge. The fuel gauge should read E (empty) or below. Key Off. Wait 30 seconds. Set the tester to 160 ohms. Key On Engine Off (KOEO). Observe the fuel gauge. The fuel gauge should read F (full) or above. Does the fuel gauge operate correctly?	Yes	Disconnect the instrument gauge system tester. Go to next step.
47		No	Disconnect the instrument gauge system tester. Go to step 8.
5	CHECK THE FUEL LEVEL SENSOR AND PUMP GROUND OPERATION Measure the resistance between the fuel level sensor and pump 0114-02 pin 1, circuit (B/W), harness side and ground. Is the resistance less than 5 ohms?	Yes	Go to step 6.
5		No	Repair circuit (B/W) for an open. Test the system for normal operation.
6	INSPECT THE FUEL TANK FOR DAMAGE Visually inspect the fuel tank for any damage or deformation. Is the fuel tank OK?	Yes	Go to next step.
6		No	Install a new fuel tank. See FUEL TANK REMOVAL / INSTALLATION . Test the system for normal operation.
7	CHECK THE FUEL LEVEL SENSOR NOTE: The fuel level sensor resistance will measure between 15 ohms +/- 2 ohms at the lower stop position and 160 ohms +/- 4 ohms at the upper stop position. Remove the fuel pump module. NOTE: Disconnect the fuel level sensor input wire from the fuel level sensor for this measurement. Measure the resistance between the fuel level sensor input wire and the fuel level sensor ground while moving the float arm between the upper stop and the lower stop position. Does the resistance fall within specifications?	Yes	Repair as necessary. See FUEL PUMP REMOVAL / INSTALLATION . Test the system for normal operation.
7		No	Install a new fuel level sender. See FUEL PUMP REMOVAL / INSTALLATION . Test the system for normal operation.
8	CHECK CIRCUIT (Y/W) FOR AN OPEN Key OFF. Disconnect: Instrument cluster 0922-101. Measure the resistance between the fuel level sensor and pump 0114-02 pin 2, circuit (Y/W), harness side and the instrument cluster 0922-101 pin 7, circuit (Y/W), harness side. Is the resistance less than 5 ohms?	Yes	Go to See step 9.
8		No	Repair circuit (Y/W) for an open. Clear the DTCs. Repeat the self-test.
9	CHECK CIRCUIT (Y/W) FOR A SHORT TO GROUND Key OFF. Measure the resistance between the instrument cluster 0922-101 pin 7, circuit (Y/W), harness side and ground. Is the resistance greater than 10,000 ohms?	Yes	Go to step 11.
9		No	Go to next step.
10	CHECK THE PCM OPERATION Key OFF. Disconnect: PCM 0140-175. Measure the resistance between the instrument cluster 0922-101 pin 7, circuit (Y/W), harness side and ground. Is the resistance greater than 10,000 ohms?	Yes	Go to step 13.
10		No	Repair circuit (Y/W) for a short to ground. Clear the DTCs. Repeat the self-test.
11	CHECK CIRCUIT (Y/W) FOR VOLTAGE Disconnect: Fuel level sensor and pump 0114-02. Connect: Instrument cluster 0922-101. Key ON. Measure the voltage at the fuel level sensor and pump 0114-02 pin 2, circuit (Y/W), harness side and ground. Is the voltage greater than 8.3 volts?	Yes	Install a new fuel level sender. Test the system for normal operation.
11		No	Go to next step.
12	CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Disconnect all the instrument cluster connectors. Check for: - corrosion - pushed-out pins Connect all the instrument cluster connectors and make sure they seat correctly. Operate the system and verify the concern is still present. Is the concern still present?	Yes	Install a new instrument cluster. See INSTRUMENT CLUSTER . Test the system for normal operation.
12		No	The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. Clear the DTCs. Repeat the self-test.
13	CHECK FOR CORRECT PCM OPERATION Disconnect the PCM connector. Check for: - corrosion - pushed-out pins Connect the PCM connector and make sure it seats correctly. Operate the system and verify the concern is still present. Is the concern still present?	Yes	Install a new PCM. See POWERTRAIN CONTROL MODULE (PCM) REMOVAL / INSTALLATION . Test the system for normal operation.
13		No	The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. Clear the DTCs. Repeat the self-test.