Pinpoint Test 1

Flow Chart No. 1 - Symptom - Fuel level reads inaccurately.

Step 1
Verify power at Fuse 11 (7.5 A) - load side.
1. Key on.




2. Using voltmeter, verity system voltage at the load side of Fuse 11 (7.5 A).




3. Is the voltage greater than 10 volts?

Step 2
Verify power at Fuse 11 (7.5 A) - feed side.
1. Key on.
2. Using voltmeter, verify system voltage at the feed side of Fuse 11 (7.5 A).




3. Is the voltage greater than 10 volts?

Step 3




Verify power at Pin 4 (R/Y) of 16-pin cluster connector.
1. Have cluster connector(s) remain intact.
2. Partially remove the instrument cluster from the instrument panel.
3. Key on.
4. Measure the voltage at Pin 4 (R/Y) at the 16-pin instrument cluster connector to ground.




5. Is the voltage greater than 10 volts?

Step 4
Verify ground at Pin 11 (B/W) of 12-pin cluster connector.

CAUTION
^ Before checking the continuity of any circuit, make sure there is no voltage present in the circuit prior to switching the test equipment to the resistance function to avoid damage to equipment. Refer to the test equipment user's manual for additional information.




1. Using an ohmmeter, check the continuity of the ground wire at the 12-pin instrument cluster connector to ground.




2. Is the resistance less than 1 ohm?

Step 5
Check fuel gauge (empty).
1. Key off.
2. Disconnect the fuel gauge sending unit.




3. Connect one lead of the SST 4908 39285 or equivalent to the fuel sending unit input wire Y/W at the fuel gauge sending unit connector. Connect the other lead to ground.
4. Set the tester to 22 ohms.
5. Key on.
6. Wait one minute.
7. Read the gauge.




8. Does the fuel gauge read E (empty)?

Step 6
Recheck fuel gauge (empty).
1. Place the key in the OFF position. Then turn to the ON position. Tap on the instrument panel.
2. Wait one minute.
3. Read the fuel gauge.




4. Does the fuel gauge read E (empty)?

Step 7
Check printed circuit board.
1. Key off.




2. Disconnect the instrument cluster.
3. Measure the resistance of the circuit between the "12" terminal printed circuit board and the 2nd terminal from right side on circuit board for anti-slosh module.




4. Is the resistance less than 1 ohm?

Step 8
Check fuel sending unit wire.
1. Key off.




2. Disconnect the instrument cluster and the fuel gauge sending unit.
3. Measure the resistance of fuel gauge sender wire Y/W between the instrument cluster and the fuel gauge sending unit.




4. Is the resistance less than 1 ohm?

Step 9
Check lock fuel sending unit ground.
1. Key off.




2. Measure the resistance of B/Y wire at the fuel gauge sending unit connector to ground at battery.




3. Is resistance less than 1 ohm?

Step 10
Check fuel gauge (full).
1. Key off.




2. Disconnect the fuel gauge sending unit.
3. Connect one lead of the SST 4908 39285 or equivalent to the fuel sending unit input wire Y/W at the fuel gauge sending unit connector. Connect the other lead to ground.
4. Set the tester to 145 ohms.
5. Key on.
6. Wait one minute.
7. Read the gauge.




8. Does the fuel gauge read F (full)?

Step 11
Fuel tank inspection.
1. Inspect fuel tank for distortion or damage.




2. Is fuel tank damaged?

Step 12
Fuel sender check - empty stop.







1. Connect one lead to ohmmeter to the fuel sender signal lead Y/W wire and the other lead to sender ground B/Y wire.




2. Does ohmmeter read 14 - 18 ohms when the float rod is against the empty stop (closest to fuel filter)?

Step 13
Fuel sender check - full stop.







1. Connect one lead of ohmmeter to the fuel sender signal lead Y/W wire and the other lead to sender ground B/Y wire.




2. Does ohmmeter read 154 - 162 ohms when the float rod is against the full stop (closest to the fuel filter)?

Step 14
Test box check - float rod travel.







1. Connect one lead of ohmmeter to the fuel sender signal lead Y/W wire and the other lead to sender ground B/Y wire.
2. Move float rod slowly from full to empty stop position.




3. Does ohmmeter reading decrease slowly?

Step 15
Harness connector check - empty stop




1. Reattach all fuel indication connectors.
2. Move float rod to empty stop position.
3. Place key in ON position.
4. Wait one minute.
5. Read fuel gauge.




6. Does fuel gauge read empty?

Step 16
Harness connector check - full stop




1. Reattach all fuel indication connectors.
2. Move float rod to full stop position.
3. Place key in ON position.
4. Wait one minute.
5. Read fuel gauge.




6. Does fuel gauge read full?

Step 17
Inspect fuel sender.
1. Inspect float and float rod.




2. Is float rod distorted, hitting filter, filled with fuel or loose on float rod?