GM Service Manual Online
For 1990-2009 cars only

Step

Action

Value(s)

Yes

No

1

Did you perform Instrument Cluster System Check?

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Go to Step 2

Go to Instrument Cluster System Check

2

  1. Turn the ignition switch to LOCK.
  2. Disconnect the powertrain control module (PCM) connector C1.
  3. Disconnect the fuel level sensor.
  4. Connect the red lead of the J 33431-C to fuel level sensor connector cavity 2.
  5. Connect the other lead to ground.
  6. Set the resistance dial on the tester to 120 ohms, 32 ohms, and 3 ohms.

Does the fuel gauge indicate the appropriate reading at the specified resistance values?

E at 120 ohms

Half tank at 32 ohms

F at 3 ohms

Go to Step 3

Go to Step 6

3

Test for an open in the BLK wire between the fuel level sensor and G400 using a J 39200 .

Does an open exist?

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Go to Step 4

Go to Step 5

4

Repair the open in the BLK wire between the fuel level sensor and G400. Refer to Wiring Repairs in Wiring Systems.

Is the repair complete?

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Go to Instrument Cluster System Check

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5

Replace the fuel level sensor.

Is the repair complete?

--

Go to Instrument Cluster System Check

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6

  1. Disconnect the J 33431-C .
  2. Disconnect the instrument panel cluster assembly connector C3.
  3. Use a J 39200 digital multimeter in order to probe the instrument panel cluster assembly connector C3 from terminal 9 to the fuel level sensor connector cavity 2.
  4. Measure the resistance.

Is the resistance greater than the specified value?

5.0 ohms

Go to Step 7

Go to Step 8

7

Repair the open in the YEL/RED wire between the instrument panel cluster assembly and the fuel level sensor. Refer to Wiring Repairs in Wiring Systems.

Is the repair complete?

--

Go to Instrument Cluster System Check

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8

Inspect for high resistance in the instrument panel cluster printed circuit.

Does high resistance exist?

--

Go to Step 9

Go to Step 10

9

Repair the instrument panel cluster printed circuit.

Is the repair complete?

--

Go to Instrument Cluster System Check

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10

Replace the fuel gauge. If the problem persists, refer to Driveability and Emissions in Engine Controls in order to diagnose the PCM (fuel level sensor circuit).

Is the repair complete?

--

Go to Instrument Cluster System Check

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