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Discussion Starter · #1 · (Edited)
Got a 2.4L 2004 Hyundai Sonata base model. I have tried 3 entirely different NEW complete fuel pumps (the entire drop-in assembly with the sending unit, and float, strainer, and all) and the fuel gauge is still constantly showing empty. Also have replaced the fuel pump/ECM relay. The car runs fine, we just have to monitor our miles for fill-ups. It's obviously got to be a problem in the wiring or the gauge itself (yet all other gauges work fine). The only DTC code I have is a TPS malfunction, which I'm about to replace. Can someone please tell me a good way to test the wiring or the gauges to narrow down the problem? Thanks!
 

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It looks like you have it narrowed down already. I do not know what else may be on that circuit, but I expect that you may two or three connectors involved in the cabling. I have seen several times that a connector cleaning solved an instrument problem. Sometimes it is a dirty ground connection. The agony is checking it all out, a wire and a connector at a time. Sorry no simple one-shot fix. Hope you find it soon as it is very awkward guessing your fuel reserve.
 

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I think it might be the time to get a Haynes manual or some other manual with wiring diagrams. I have had some luck with the advance auto website. They provide some wiring diagrams if you start an account. If you can determine the connectors and pin outs you need you can check the wires starting at the sender or the gauge and narrow down where the open may be if it is not a component. You have proven it is not the pump/sender unit. As David said I think it would be a good possibility to check the connectors for corrosion especially under the car.
 

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Discussion Starter · #5 ·
I haven't had a whole lot of time to deal with this car, but it's still driving fine.

So I finally hook a diagnostics tool to it and I found P0463 for Fuel Level Sensor Circuit High (it used to only have one code before). I tried grounding the pink wire to the ground and the gauge didn't move at all. I read ohms on the matching plugs on the fuel pump and was able to see about 40ohms. So the pump is working, now what else is causing the gauge not to work?
 

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I suspect you have either very high resistance at a connector due to corrosion, an open or a short between the fuel sender and the ECM. If I had time I would identify and check resistance of the wiring from the sender to the ECM. If all the wires were 2 to 3 ohms or less with no shorts to each other or ground, I would suspect the gauge. If it is running fine, I would probably just use the trip meter as a rudimentary fuel gauge. That is how we fuel my daughters escort as its fuel quantity is also inop. We get to 200 mile and fill er up and reset.
 
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