Got a '96 with a fuel gauge that always reads E. I know how to test it at the fuel pump harness *if* I can find a pinout of the harness. It seems like I can find every year except 96.

If you've got a 96 wiring diagram, or can tell me which wires at that connector are what, or have any other insight on the gauge issue, that would be great.

Is there a standalone sender in the tank I can check? Or is it integrated into the pump like most every other modern car? It seems like '96 is just an odd duck year.

 

Check with 5-90, he is an XJ wiring ninja!! I bet he would have what you need...

https://www.cherokeeforum.com/members/5-90-711/

 

I pulled the pump and made sure that the float isn't cracked and, well, floats. Then I ran the sensor through its entire range to make sure the resistance swept smoothly, which it did.

Then I pulled the cluster and removed the fuel gauge. I hooked up 12 volts between the IGN and LG pins and it went all the way to empty, then ground the FU pin and it swept to full. So the gauge works.

What I need now is a test procedure for the vehicle side of the harness, which is definitely different from 95-down and seems to be different from 97+.

 

I have a '96 with the same problem. You say you ran the sensor (rheostat) through its entire range......were you using an ohm meter, or just moving it by hand? I ask this because I found that after removing the float arm & examining the metal pick-up, I found that it had a small piece broke out of it. I then touched it & it fell apart.....almost like dust. It seems that ethanol worked its magic....as the jeep sat for about a year with an empty tank.

John

 

I hooked up an ohmmeter to the middle two pins on the 6-pin pump connector and then moved the float through its range by hand.

 

Good to hear it tested OK.......apparently that is one part that is almost impossible to find in the aftermarket world. I found ONE place, in upstate NY, that would replace the rheostat....if I send it to them. I plan on hitting a few salvage yards before going that route. Good luck with your problem.

John