Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSPLYMOUTH1994SUNDANCE BASE, 2D HATCHBACK, 2.2 D, AUTOMATICREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 14 (INSTRUMENT PANEL (CONVERTIBLE))TESTINGFUEL GAUGE SENDING UNIT TEST
1994 Plymouth Sundance Base, 2D Hatchback, 2.2 D, Automatic
Fuel Gauge Sending Unit Test
1994 Plymouth Sundance Base, 2D Hatchback, 2.2 D, AutomaticSECTION Fuel Gauge Sending Unit Test
WARNING: This page is about a different car, the 1994 Chrysler LeBaron. However, it is still accessible from the selected car via links, so may be relevant.
- Remove cluster bezel from instrument panel. Remove fuel gauge retaining screws (if equipped). Remove fuel gauge by pulling straight out from cluster. DO NOT turn or twist gauge when pulling, or severe damage to cluster pins will result.
- Turn ignition on. Using voltmeter, check for battery voltage at fuel gauge (B+) pin. See Fig 1 . Using ohmmeter, check for ground continuity at fuel gauge ground pin. If voltage and ground are not present at pins, go to step 3). If voltage and ground are present at proper pins, go to step 5).
- If voltage and ground are not present at pins, remove instrument cluster. See INSTRUMENT CLUSTER under REMOVAL & INSTALLATION. See Figure . Check for battery voltage and ground at appropriate cluster harness connectors. See WIRING DIAGRAMS .
- If voltage and ground are not present at cluster harness connectors, repair wiring as necessary. If voltage and ground are present at cluster harness connectors, check cluster for bent or broken terminal pins. If terminal pins are okay, replace cluster printed circuit board and retest.
- To check sending unit resistance, remove fuel sending unit from tank. Ensure fuel sending unit is not damaged. Reconnect tank sending unit to harness connector. Ensure sending unit and connector are properly grounded to vehicle.
- Position sending unit float to FULL position. Using ohmmeter, check resistance reading at fuel sender input pin of cluster. See Fig 1 . If reading is infinity, repair open in wiring circuit from cluster to sending unit. Correct reading should be within 4 ohms of specification. See FUEL GAUGE CALIBRATION . Position sending unit to other positions and check resistances to match table.
- If sending unit resistances do not match table, replace sending unit. After ensuring sending unit resistances are satisfactory, with ignition off, position fuel gauge onto cluster pins and install by pushing gauge straight inward onto pins.
- Turn ignition on. Position sending unit to previously checked resistance positions and note position of fuel gauge after 15 seconds. If fuel gauge pointer position is not relative to sending unit position, replace fuel gauge.
FUEL GAUGE CALIBRATION
| Resistance | Position |
|---|---|
| 90 Ohms | E |
| 59 Ohms | 1/4 |
| 42 Ohms | 1/2 |
| 28 Ohms | 3/4 |
| 12 Ohms | F |
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.