I have a 1999 Sunfire and the fuel pump fuse kept blowing. I noticed it happened during accelerations only. After tracing this son of gun down by placing a jumper fuse between the fuel pump and the fuse box and also one from the fuse box to the relay that goes under the hood; i found the problem kept coming between the fuse box and engine. Make long story short I found the problem with a corroted positive battery cable (the main red cable). I could not tell before because it is insulated; but once i cut it, the problem was obvious when i saw all the green **** on the wires. I replaced the cable with a new one and the fuse blowing stopped. Hops this helps...........It drove me crazy for 5 months.
Hello mcammdf. To properly test the fuel gauge circuit you will need to check the purple wire at the connector to the fuel tank. Run a wire from the purple wire at the connector to body ground. If the gauge moves when you ground it the circuit to that point is good. These cars are noted for fuel gauge problems and most probably the issue will be the sending unit in the fuel tank.
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Is the security light lit on the instrument cluster ? The vehicle has spark ? Does it have fuel pressure ? Did you check with a fuel pressure gauge ? The passlock anti-theft system use's a sensor in the ignition lock assembly .
The Passlock™ lock cylinder is a locking cylinder that turns a rotating magnet past a stationary hall effect sensor. The rotating magnet creates a resistance code (R-Code) that the cylinder sends to the instrument cluster. The Passlock™ lock cylinder interfaces with the instrument cluster through a 3 wire connection. The 3 wires have the following functions:
Plus software programmed into the instrument cluster and PCM/ECM engine computer .
There is nothing you can do if the anti-theft system is not working , taking out parts won't do any thing , the software in the computers still won't let it start . Your best bet ,take it to a GM dealer .
Anytime when there is multiple issues, I pick one system when the problem is ongoing, check voltage and ground.
The fuses in picture is for instrument cluster, Check for voltage at the fuses when problem is ongoing. Use a test lite. As you can see, one fuse is hot all the time, the other goes hot with the key on.
The gauge problem sounds like the common issue on the 03-05 Sunfire instrument clusters where the stepper motors on the cluster's circuit board fail over time. It can be fixed, check out this page for more on how to get it repaired - Sunfire instrument cluster fix
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