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 Post subject: Fuel gauge debugging
PostPosted: Sun Aug 22, 2004 10:00 pm 
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The Silent Administrator
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Joined: Wed Dec 24, 2003 3:32 pm
Posts: 9359
Location: Ottawa, ON, Canada
Here is what I just read in the manual about diagnosing the fuel gauge:
Quote:
*When the ignition switch is turned to "ON", currents flows through fuse No. 7, fuel gauge, fuel gauge unit and ground, in turn operating the fuel gauge.
*When fuel level is high, the fuel gauge unit internal resistance is small so that the current passing through the circuit is relatively large. This causes the gauge pointer to swing towards "F".
*When fuel level becomes low, the unit internal resistance is increased, so only a small current flows the circuit and the gauge pointer swings towards "E".
*Inside the fuel gauge, there is a voltage limiter which functions to maintain a constant output voltage (at 7 V) to the gauge units (fuel gauge unit and engine coolant temperature unit).
Quote:
Cluster with tach, Type 2
With the back of the cluster facing you, there is an upper most LARGER bulb location on the right hand side; to the right of that line of 5 holes running top to bottom (some have bulbs and others may be holes?).
Start tracing your way to the first LARGE twist in bulb connector going left from the line of 5 holes; the hole test point D should be just to the left of this with C first on the left of D still. Moving along the top of the cluster back the next two test points will align just to right of a long line of bulb locations or holes (diagram playing tricks on me!) this starting on the right is test hole B and then on the left of B is A just slightly lower.
->Fuel gauge unit resistance value - ohms
-- Float point "F" 3 (+/-) 2
-- Float point "E" 110 (+/-) 7
->Fuel gauge unit float position - mm(in.)
-- Float point "F" - 12-14 (.47-.55)
-- Float point "E" - 125-127 (4.92-5.0)
Standard value
->Fuel gauge resistance value - ohms
--Between terminals A and B = 77 - 93
--Between terminals A and C = 59 - 71
--Between terminals B and C = 76 - 92
Standard value
-->Engine coolant temperature guage circuit inspection in ohms
--Between terminals B and D = 144 - 174
--Between terminals C and D = 68 - 82
--Between terminals B and C = 76 - 92
Sounds like alot of circuits are coming through fuse #7 - does it check out too? There were other circuits coming through fuse #7 as I was reading further.
Quote:
Fuel gauge simple inspection
1. Remove the rear seat cushion and remove the plug located on the rear floor.
2. Remove the connector of the fuel gauge unit located at the top of the fuel tank.
3. Ground the harness side connector via a test light (12V-3.4W).
4. Turn ON ignition key.
5. Assure test light goes on and gauge needle moves.
If the test light goes on but gauge needle does not move, replace fuel gauge.
6. If test light does not go on (and gauge needle does not move), check fuse for broken wire, or resistance between gauge terminals, or break in harness. Replace or repair defective parts.

Engine Coolant Temperature Gauge Simple Inspection
1. Remove connector from engine coolant temperature gauge unit in engine compartment.
2. Groudn harness side connector via test light (12V-3.4W).
3. Turn ON ignition key.
4. Check that test light goes on and gauge needle moves.
5. If test light goes on but the gauge needle does not move, replace engine coolant temperature gauge.
If test light does not go on (and gauge needle does not move), check fuse for broken wire, or resistance between gauge terminals, or break in harness. Replace or repair defective parts.
Picked from the 1991 Dodge Colt/Summit/Colt 200 Chrysler Corporation Service Manual.


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