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TEST 36A - Repairing Fuel Level Problem

NOTE: For connector terminal identification, see CONNECTOR IDENTIFICATION . For appropriate wiring diagram, see WIRING DIAGRAMS .
  1. Using DRB-II, stop actuator test. Disconnect fuel pump/sending unit harness connector. Connector is located underneath vehicle along frame rail. Check connector, and clean or repair connector as necessary. Using DRB-II, read fuel level sensor voltage.
  2. If voltage is more than 8 volts, go to step 5). If voltage is less than 8 volts, turn ignition switch to OFF position. Disconnect body controller Blue connector. Check connector, and clean or repair connector as necessary.
  3. Turn ignition switch to ON position. Put DRB-II in voltmeter mode. Probe terminal No. 6 (Dark Blue/White wire) of body controller Blue connector. If voltage is less than 10 volts, repair open Dark Blue/White wire. Perform VERIFICATION TEST - VERIFICATION OF REPAIRS . If voltage is more than 10 volts, turn ignition switch to OFF position.
  4. Put DRB-II in ohmmeter mode. Probe terminal No. 18 (Dark Blue wire) of body controller Blue connector. If resistance is less than 5 ohms, repair short to ground in Dark Blue wire. Perform VERIFICATION TEST - VERIFICATION OF REPAIRS . If resistance is more than 5 ohms, replace body controller. Perform VERIFICATION TEST - VERIFICATION OF REPAIRS .
  5. If voltage is more than 8 volts in step 2), connect a jumper wire between Dark Blue and Black wires of fuel pump/sending unit connector. Using DRB-II, read fuel level sensor voltage. If DRB-II displays 0.0 VOLTS, replace fuel level sensor. Perform VERIFICATION TEST - VERIFICATION OF REPAIRS .
  6. If DRB-II does not display 0.0 VOLTS, disconnect jumper wire. Connect a jumper wire between Dark Blue wire of fuel pump/sending unit connector and ground. If DRB-II displays 0.0 VOLTS, repair open Black wire. Perform VERIFICATION TEST - VERIFICATION OF REPAIRS . If DRB-II does not display 0.0 VOLTS, disconnect jumper wire. Access body controller.
  7. Body controller is located under left side of instrument panel. Connect a jumper wire between terminal No. 18 (Dark Blue wire) at wiring harness side of body controller Blue connector and ground. If DRB-II displays 0.0 VOLTS, repair open Dark Blue wire. Perform VERIFICATION TEST - VERIFICATION OF REPAIRS . If DRB-II does not display 0.0 VOLTS, turn ignition switch to OFF position. Disconnect body controller. Check connectors, and clean or repair connectors as necessary. Replace body controller. Perform VERIFICATION TEST - VERIFICATION OF REPAIRS .
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