Possible Causes

Circuit (Y/V) open or short to ground
Circuit (B/W) open
Fuel tank
Fuel pump module
Fuel pump sensor
Instrument cluster

CAUTION:

Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.

NOTE:

It is Critical to follow the pinpoint test diagnostic methods to make sure the correct mode is being used during diagnostics.

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. Select and scroll the fuel gauge 20%, 50% and 70%. Does the fuel gauge indicate approximately 1/4 tank at 20%, 1/2 tank at 50% and 3/4 tank at 70%?	Yes	Go to next step.
1		No	Go to step 11.
2	RETRIEVE THE RECORDED 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	If DTC B1202 is retrieved, go to next step. If DTC B1204 is retrieved, go to step 5
2		No	Go to step 7.
3	CHECK THE FUEL PUMP MODULE FOR AN OPEN NOTE: Be sure to locate and use a known good, clean ground source for this test. Failure to ensure a good ground may result in inaccurate test results. Key OFF. Disconnect: Fuel pump module 0114-02, 0922-102. Connect a fused (5A) jumper wire between the fuel pump module 0114-02 pin 2, circuit (Y/V) and ground. Key ON. Wait one minute. Clear the DTCs. Carry out the instrument duster self-test diagnostics. NOTE: DTC B1202 may also be present when carrying out this step and should be ignored. Retrieve the continuous memory DTCs. Is DTC B1204 present?	Yes	Go to step 8.
3		No	Go to next step.
4	CHECK CIRCUIT (Y/V) FOR AN OPEN Key Off. Disconnect: Instrument cluster 0922-101. Measure the resistance between the fuel pump module 0114-02 pin 2, circuit (Y/V), harness side and the instrument cluster 0922-101 pin 7, circuit (Y/V), harness side. Is the resistance less than 5 ohms?	Yes	Go to step 11.
4		No	Repair the circuit. Clear the DTCs. Repeat the self-test.
5	CHECK THE FUEL PUMP MODULE FOR A SHORT TO GROUND Key OFF. Disconnect: Fuel pump module 0114-02, 0922-102. Key ON. Wait one minute. Clear the DTCs. Carry out the instrument cluster self-test diagnostics. NOTE: DTC B1204 may also be present when carrying out this step and should be ignored. Retrieve the continuous memory DTCs. Is DTC B1202 present?	Yes	Go to step 10.
5		No	Go to next step.
6	CHECK CIRCUIT (Y/V) FOR A SHORT TO GROUND Key OFF. Measure the resistance between the instrument cluster 0922-101 pin 7, circuit (Y/V), harness side and ground. Is the resistance greater than 10,000 ohms?	Yes	Go to step 11.
6		No	REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
7	CHECK THE FUEL LEVEL SENSOR AND PUMP GROUND FOR AN OPEN Key OFF. Measure the resistance between the fuel pump module 0114-02 pin 1, circuit (B/W), harness side and ground. Is the resistance less than 5 ohms?	Yes	Go to step 10.
7		No	REPAIR the circuit. TEST the system for normal operation.
8	CHECK THE FUEL GAUGE OPERATION NOTE: It is extremely important to confirm the gauge system settings with an ohm-meter to ensure that the gauge system tester settings are in the correct position. Failure to follow this check may result in inaccurate test results. Key OFF. NOTE: The fuse must be removed to reset the fuel gauge timers. Failure to complete this step may result in erroneous test results. Remove the smart junction box (SJB) fuse 33 (5A). Wait 1 minute and reinstall the fuse. NOTE: Be sure to locate and use a known good, clean ground source for this test. Connect one lead of the instrument gauge system tester to fuel pump module 0114-02 pin 2, circuit (Y/V), harness side. Connect the other lead to ground. Set the tester to 10 ohms. Key ON. On vehicles equipped with an automatic transmission, apply the brake and move the transmission shift lever from PARK (P) to DRIVE (D). Wait 10 seconds, and move the transmission shift lever back to PARK (P). Wait 30 seconds. Do not change the tool settings or the ignition switch position until 30 seconds have elapsed. On vehicles equipped with a manual transmission, apply the parking brake. Wait 10 seconds, and release the parking brake. Wait 30 seconds. Do not change the tool settings or the ignition switch position until 30 seconds have elapsed. Key OFF. Set the tester to 180 ohms. Key ON. On vehicles equipped with an automatic transmission, apply the brake and move the transmission shift lever from PARK (P) to DRIVE (D). Wait 10 seconds, and move the transmission shift lever back to PARK (P). Wait 30 seconds. Do not change the tool settings or the ignition switch position until 30 seconds have elapsed. On vehicles equipped with a manual transmission, apply the parking brake. Wait 10 seconds, and release the parking brake. Wait 30 seconds. Do not change the tool settings or the ignition switch position until 30 seconds have elapsed. Key OFF. Wait 30 seconds. Do not change the tool settings or the ignition switch position until 30 seconds have elapsed. Set the tester to 10 ohms. Key ON. On vehicles equipped with an automatic transmission, apply the brake and move the transmission shift lever from PARK (P) to DRIVE (D). Wait 10 seconds, and move the transmission shift lever back to PARK (P). Wait 30 seconds. Do not change the tool settings or the ignition switch position until 30 seconds have elapsed. On vehicles equipped with a manual transmission, apply the parking brake. Wait 10 seconds, and release the parking brake. Wait 30 seconds. Do not change the tool settings or the ignition switch position until 30 seconds have elapsed. Observe the fuel gauge. The fuel gauge should read F (full) or below. Key OFF. Wait 30 seconds. Do not change the tool settings or the ignition switch position until 30 seconds have elapsed. Set the tester to 180 ohms. Key ON. Observe the fuel gauge. The fuel gauge should read E (empty) within one minute. Key OFF. Does the fuel gauge operate correctly?	Yes	DISCONNECT the instrument gauge system tester. Go to step 9.
8		No	DISCONNECT the instrument gauge system tester. Go to step 11.
9	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.
9		No	Install a new fuel tank. See FUEL TANK REMOVAL / INSTALLATION , . Test the system for normal operation.
10	CHECK THE FUEL LEVEL SENSOR Key OFF. NOTE: The fuel level sensor resistance will measure between 10 ohms ± 2 ohms at the upper stop position and 180 ohms ± 4 ohms at the lower stop position. Remove the fuel pump module. See FUEL PUMP REMOVAL / INSTALLATION , . 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 slowly moving the float arm between the lower stop and the upper stop position Does the resistance slowly increase from approximately 10 ohms to 180 ohms?	Yes	Install a new fuel pump module. See FUEL PUMP REMOVAL / INSTALLATION , . TEST the system for normal operation.
10		No	INSTALL a new fuel level sensor. See FUEL PUMP REMOVAL / INSTALLATION , . TEST the system for normal operation.
11	CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Disconnect all the instrument cluster connectors. Check for: corrosion damaged pins 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.
11		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.