Repair Procedure
Use the troubleshooting chart to determine the applicable repair procedure.
Caution
^ Use the applicable Workshop Manual and Wiring Diagram Manual to perform the following procedures.
Repair Procedure # 1 - Testing Fuel Tank Sending Units
1. Remove both the No. 1 and No. 2 tank gauges to see if a black sticky substance (foreign material) is deposited on the resistor portion of the gauge. If any, replace the gauges (T001 60 970C or T001 60 960B). The sticky substance is difficult to remove.
2. Use the table and make sure the resistance range is within specification for each fuel tank gauge. Perform a resistance sweep test and make sure there are no drop outs or sudden change in resistance while moving the level slowly from the up to the down position.
If resistance is out of range or has sudden drop outs, replace the affected gauge. Refer to table and illustration for more details.
Repair Procedure # 2 - Wire Harness Inspection
1. Connect a voltmeter to the G/Y wire of the fuel gauge sender unit, then connect the other wire of the voltmeter to ground and turn the key to "N".
2. Perform a wiggle test to each of the following connectors: C-01, X-25, B1-09(KL), B2-05(KJ), X-13, C-08 and C-09. Note any change in voltage as a result of a poor connection and correct the problem.
Repair Procedure # 3 - Wire Harness Inspection
1. Remove the rear seat cushion. Disconnect the B1-09 (KL engine) or the B2-05 (KJ engine) connector. Connect an ohmmeter between the G/Y wire in the connector on the fuel gauge sender unit side and the body ground. Verify that there is an infinite amount of resistance (no connection) between the G/Y wire and body ground.
If there is not infinite resistance, locate and repair short in the harness between the connector and the fuel gauge sender units.
If there is infinite resistance, proceed to STEP 2.
2. Remove the instrument cluster assembly (meter assembly) disconnecting the center connector per the Workshop Manual. Verify that the resistance is less than 1 ohm between connector B1-09 (KL ENGINE) or B2-05 (KJ ENGINE) and the G/Y wire at the instrument cluster assembly.
If less than 1 ohm a short to ground exists in harness. Locate and repair short.
If greater than 1 ohm, a poor electrical connection exists. Locate and repair poor connection.
Repair Procedure # 4 - Checking Body Grounds
Using an ohmmeter, verify that the B/R wire has less than 1 ohm continuity between the fuel gauge sender connector C-09 and the body ground.
Note
^ Be sure all accessories are off and that none of the courtesy lights are illuminated. Any current flow through the battery will cause a higher than normal resistance between C-09 and body ground.
If greater than 1 ohm or no resistance is found a poor connection exists in the ground circuit. Perform the following test and locate the poor connection.
- Check ground point location 4 or 5 for tight connection.
- Check all connectors between C-09 and 4 or 5 for poor connections.
- Use wiring diagram to determine location of ground point and connectors.
If 1 ohm or less, proceed to STEP 5.
Repair Procedure # 5 - Fuel Meter Testing
1. Remove instrument cluster assembly without disconnecting the connectors.
2. Turn key "ON" and measure the voltage between the following wires on the backside of the instrument cluster. Refer to illustration.
If the voltages are the same, an internal short exists. Replace print plate # 2. If the voltages are different, proceed to STEP 3.
3. Measure the resistance between the wires screwed to the back of the instrument cluster. Use the illustration above and the specifications below. Replace the fuel meter if out-of-specification.
Specification
165 - 210 ohms: Terminals L and B
135 - 180 ohms: Terminals B and Y
23 - 33 ohms: Terminals Y and L