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Instrument Cluster Test 3E - Measuring Fuel Gauge Accuracy

NOTE: Perform INSTRUMENT CLUSTER TEST 3A  before proceeding with this test. For connector terminal ID, see CONNECTOR IDENTIFICATION  and WIRING DIAGRAMS  . Perform TEST VER-1A - VERIFICATION PROCEDURE  after each repair.
CAUTION: Always turn ignition switch to OFF position prior to disconnecting or connecting any module connector.
  1. Using scan tool, actuate gauges. Observe fuel gauge. If fuel gauge pointer sweeps and stops at E, 1/8, 1/4 and Full, go to next step. If fuel gauge does not operate correctly, recalibrate fuel gauge using scan tool.
  2. Stop actuation. Inspect fuel tank for bowing on bottom of tank. Replace as needed. If vehicle is CNG powered, go to step 6). If vehicle is gas powered, go to next step.
  3. Turn ignition off. Disconnect Body Control Module (BCM) connector "B". BCM is located with junction block under driver's side instrument panel. See Figure in CHIME TEST 2A. Go to next step.
  4. Using scan tool in ohmmeter mode, measure resistance between chassis ground and BCM connector "B", terminal No. 46 (Dark Blue). Determine if ohmmeter reading matches fuel level. See FUEL LEVEL SENDING UNIT RESISTANCE table. If resistance matches fuel gauge reading, replace BCM. If resistance does not match fuel gauge reading, go to next step.
    FUEL LEVEL SENDING UNIT RESISTANCE

    Float Position Float Height - In. (mm) Ohms
    Full 5.4-5.8 (137-147) 50-90
    3/4 3.8 (97) 310-370
    1/2 2.6 (66) 520-580
    1/4 1.4 (35) 730-790
    Empty -.14-.18 (-3.5-4.6) 1020-1080
  5. Remove fuel level sending unit from fuel tank. Inspect tank unit for foreign material. Replace as needed. If tank is okay, replace sending unit.
  6. Disconnect fuel gauge pressure sensor. Using external voltmeter, measure voltage between ground and terminal No. 2 (Brown/Pink wire) on fuel gauge pressure sensor connector. If voltage is 10 volts or less, repair open Brown/Pink wire. If voltage is more than 10 volts, go to next step.
  7. Using external ohmmeter, measure resistance between ground and terminal No. 1 (Black wire) on fuel gauge pressure sensor connector. If resistance is less than 20 ohms, replace fuel gauge pressure sensor. If resistance is 20 ohms or greater, repair open Black wire.
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