GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Corvette 🢒 Body and Accessories 🢒 Instrument Panel, Gages, and Console 🢒 Fuel Gage Inaccurate or Inoperative

Diagnostic Aids
    • Ensure that the fuel level is in the same range as the customer concern.
    • For intermittent diagnosis, refer to Testing for Intermittent Conditions and Poor Connections in Wiring Systems.
    • Refer to Fuel Level Specifications in order to verify the correct fuel level sensor readings. The Fuel Tank Level Remaining (%) parameter is available on the scan tool in the PCM Enhanced EVAP data list.

Important: When inspecting for a deformed or warped fuel tank, measure the resistance of the suspect fuel level sensor at empty, with the sensor in the fuel tank, and again with the sensor removed from the fuel tank. The measured resistance values should be the same at empty. If the measured resistance values are not the same, refer to Fuel Tank Replacement in Engine Controls.

Test Description

The number(s) below refer to the step number(s) on the diagnostic table.

  1. This step tests for a high resistance in the signal circuit and the low reference circuit of the fuel level sensor.

    2.

  2. DTCs will be set in the PCM when you perform this diagnostic table.

Step

Action

Value(s)

Yes

No

Schematic Reference: Instrument Cluster Schematics

1

Did you perform the IPC Diagnostic System Check?

--

Go to Step 2

Go to Diagnostic System Check - Instrument Cluster

2
  1. Disconnect C408.
  2. Connect a jumper wire between the signal circuit of the primary fuel level sensor and the signal circuit of the secondary fuel level sensor (female terminal side).
  3. Connect the J 33431-C Signal Generator and Instrument Panel Tester between the signal circuit of the fuel level sensor and the low reference circuit of the fuel level sensor (female terminal side).
  4. Turn ON the ignition, with the engine OFF.

    5. Important: Verify the J 33431-C resistance settings with a DMM.

  5. Vary the resistance on the J 33431-C from 40-250 ohms.
  6. Refer to Fuel Level Specifications in order to convert from resistance to fuel gage display.

Does the fuel gage display the correct fuel level?

--

Go to Step 4

Go to Step 3

3

  1. Install a scan tool.
  2. Turn ON the ignition, with the engine OFF.

    3. Important: Verify the J 33431-C resistance settings with a DMM.

  3. Vary the resistance on the J 33431-C from 40-250 ohms.
  4. Refer to Fuel Level Specifications in order to convert from resistance to fuel level percent.

    5. Important: Turn OFF the ignition momentarily between the resistance settings in order to quickly update the scan tool display.

  5. With the scan tool, observe the Fuel Tank Level Remaining percent parameter in the PCM Enhanced EVAP data list.

Does the scan tool display the correct fuel level percent?

--

Go to Step 11

Go to Step 5

4

Inspect for the following items:

    • A poor connection at the harness connector of the fuel level sensor--Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs in Wiring Systems.
    • A high resistance in the signal circuit or the low reference circuit between the fuel level sensor and C408
    • A misaligned fuel level sensor
    • A deformed fuel tank

Did you find and correct the condition?

--

Go to Step 13

Go to Step 7

5

Test the signal circuit of the fuel level sensor for a high resistance. Refer to Circuit Testing and Wiring Repairs in Wiring Systems.

Did you find and correct the condition?

--

Go to Step 13

Go to Step 6

6

Test the low reference circuit of the fuel level sensor for a high resistance. Refer to Circuit Testing and Wiring Repairs in Wiring Systems.

Did you find and correct the condition?

--

Go to Step 13

Go to Step 9

7
  1. Remove the fuel level sensor.
  2. Inspect for the following items:
    3. • A stuck fuel level sensor (i.e. the fuel strainer interfering with the sensor float arm)
    • Foreign material in the fuel tank (ice)

Did you find and correct the condition?

--

Go to Step 13

Go to Step 8

8
  1. With the DMM, measure the resistance of the fuel level sensor while moving the float arm.
  2. Observe both the analog and digital displays on the DMM.

Does the resistance change smoothly across the specified range?

40-250 ohms

Go to Diagnostic Aids

Go to Step 10

9

Inspect for poor connections at the harness connector of the PCM. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs in Wiring Systems.

Did you find and correct the condition?

--

Go to Step 13

Go to Step 12

10

Replace the fuel level sensor. Refer to Fuel Sender Assembly Replacement in Engine Controls.

Did you complete the replacement?

--

Go to Step 13

--

11

Replace the IPC. Refer to Instrument Cluster Replacement .

Did you complete the replacement?

--

Go to Step 13

--

12

Important: Program the replacement PCM.

Replace the PCM. Refer to Powertrain Control Module Replacement in Engine Controls.

Did you complete the replacement?

--

Go to Step 13

--

13

  1. Use the scan tool in order to clear the PCM DTCs.
  2. Operate the system in order to verify the repair.

Did you correct the condition?

--

System OK

Go to Step 2