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Fuel Gauge Test

  1. Turn ignition on. Observe other gauges and indicators. If other gauges do not operate normally, go to step 5). If other gauges operate normally, cluster is receiving battery voltage, and grounds are good. If testing fuel gauge with resistors, go to step 2). If testing fuel gauge with substitute fuel gauge sending unit, go to step 4).
  2. Unplug harness connector from fuel gauge sending unit. Connect 145-ohm resistor, or Gauge System Tester (021-00055) set to 145 ohms, between harness connector Yellow/White wire terminal and ground. Turn ignition on. Fuel gauge should indicate at or above FULL mark.
  3. Connect 22-ohm resistor (or tester set to 22 ohms) between harness connector Yellow/White wire terminal and ground. Turn ignition on. Fuel gauge should indicate at or below EMPTY mark. If gauge does not respond as specified, inspect for open or short circuit in wiring, or replace gauge as necessary. If gauge functions as specified, replace fuel gauge sending unit.
  4. Unplug connector from fuel gauge sending unit. Connect and ground substitute sending unit. Move sending unit float to full position. Turn ignition on. Gauge should indicate at or above FULL mark. Turn ignition off. Move float to empty position. Wait about 30 seconds. Turn ignition on. Fuel gauge should indicate at or below EMPTY mark. If gauge does not indicate as specified, inspect for open or short circuit in wiring. If wiring is okay, replace gauge as necessary. If gauge functions as specified, replace sending unit.
  5. Ensure battery voltage exists at warning indicator fuse. Partially remove instrument cluster, leaving connectors attached. Ensure cluster harness connections are secure. See INSTRUMENT CLUSTER under REMOVAL & INSTALLATION. Test for battery voltage at cluster connector by backprobing feed wire from fuse panel. Test for cluster ground circuit continuity. Repair as necessary. See WIRING DIAGRAMS.
  6. Turn ignition off. Unplug fuel gauge sending unit connector. Use Gauge System Tester (021-00055) or resistors as in step 2). If using tester, connect it to cluster side of harness connector Yellow/White wire and set to 22 ohms. If using resistors, connect 22-ohm resistor between cluster side of harness connector Yellow/White wire and ground.
  7. Turn ignition on. Wait 60 seconds. Observe fuel gauge. Fuel gauge should indicate EMPTY. If gauge does not indicate EMPTY, turn ignition off. Remove instrument cluster. Inspect printed circuit for open fuel gauge circuit. If circuit is okay, remove antislosh module from rear of cluster.
  8. Remove tester (or resistor) from harness connector. Using jumper wire, connect tester (or 22-ohm resistor) directly to fuel gauge terminal "S" on rear of cluster. Reconnect wiring harness to instrument cluster. Turn ignition on. If fuel gauge now indicates EMPTY, replace antislosh module. If fuel gauge does not indicate EMPTY, replace fuel gauge.
WARNING: Release fuel pressure before disconnecting fuel line or removing fuel gauge sending unit. Connect Fuel Pressure Gauge (T80L-9974-B) to fuel diagnostic valve on fuel rail. Open valve on fuel rail to release pressure.
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