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For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Kodiak C-Series (Crew) C6/C7/C8 🢒 Body and Accessories 🢒 Instrument Panel, Gages, and Console 🢒 Fuel Gage Inaccurate or Inoperative

Fuel Gage Inaccurate or Inoperative Single Tank

Diagnostic Aids
    • Verify 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 readings for the fuel level sensor. The Fuel Tank Level Remaining % parameter is available on the scan tool in the PCM Enhanced EVAP data list-L18 only. The fuel level sensor % parameter is available on the scan tool in the Fuel System data list-LB7 and LG4 only.

Test Description

The numbers below refer to the step numbers 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 set in the PCM when you perform this diagnostic table.

Step

Action

Value(s)

Yes

No

Schematic Reference: Instrument Cluster Schematics

Connector End View Reference: Master Electrical Component List in Wiring Systems

1

Did you perform the Instrument Cluster Diagnostic System Check?

--

Go to Step 2

Go to Diagnostic System Check - Instrument Cluster

2
  1. Disconnect the fuel level sensor.
  2. 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 on the female terminal side of the connector.
  3. Turn the ignition ON, with the engine OFF.

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

  4. Vary the resistance on the J 33431-C
  5. 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 the ignition ON, 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 .
  4. Refer to Fuel Level Specifications in order to convert from resistance to fuel level percentage.

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

  5. With the scan tool, observe one of the following fuel level parameters:
    6. • Fuel Tank Level Remaining % parameter in the PCM Enhanced EVAP data list-L18 only
    • Fuel Level Sensor % parameter in the ECM Fuel System data list-LB7 and LG4 only

Does the scan tool display the correct fuel level percentage?

--

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 to Connector Repairs in Wiring Systems.
    • A misaligned fuel level sender
    • 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 to 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 to 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 sender.
  2. Inspect for the following items:
    3. • The fuel level sensor is stuck, perhaps due to an interference with the fuel strainer.
    • The fuel tank contains foreign material, for instance, ice.

Did you find and correct the condition?

--

Go to Step 13

Go to Step 8

8
  1. With the J 39200 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 (L18 and LB7) or 0-90 ohms (LG4 and LG5)

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 to 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 - 6.6L
    • Fuel Sender Assembly Replacement in Engine Controls - 7.8L
    •  Fuel Sender Assembly Replacement in Engine Controls - 8.1L

Did you complete the replacement?

--

Go to Step 13

--

11

Important: Program the replacement IPC.

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:

    •  Engine Control Module Replacement in Engine Controls - 6.6L
    •  Engine Control Module Replacement/Restore Fuel Rate Data in Engine Controls - 7.8L
    •  Powertrain Control Module Replacement in Engine Controls - 8.1L

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

Fuel Gage Inaccurate or Inoperative Dual Tank

Diagnostic Aids
    • Verify that the fuel level is in the same range as the customer concern.
    • Certain ECM DTCs will cause the fuel gage to default to zero. Check the ECM for any DTCs.
    • 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 readings for the fuel level sensors. The Fuel Tank Level Remaining % parameter is available on the scan tool in the PCM Enhanced EVAP data list-L18 only. The Fuel Level Sensor % parameter is available on the scan tool in the Fuel System data list-LB7 and LG4 only.

Test Description

The numbers below refer to the step numbers on the diagnostic table.

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

    2.

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

Step

Action

Value(s)

Yes

No

Schematic Reference: Instrument Cluster Schematics

Connector End View Reference: Master Electrical Component List in Wiring Systems

1

Did you perform the Instrument Cluster Diagnostic System Check?

--

Go to Step 2

Go to Diagnostic System Check - Instrument Cluster

2
  1. Disconnect the primary and the secondary fuel level sensors.
  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.
  3. Connect the J 33431-C Signal Generator and Instrument Panel Tester between the signal circuit of the fuel level sensors and the low reference circuit of the fuel level sensors on the female terminal side of the connector.
  4. Turn the ignition ON, 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 .
  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 the ignition ON, 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 .
  4. Refer to Fuel Level Specifications in order to convert from resistance to fuel level percentage.

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

  5. With the scan tool, observe one of the following fuel level parameters:
    6. • Fuel Tank Level Remaining % parameter in the PCM Enhanced EVAP data list-L18
    • Fuel Level Sensor % parameter in the Fuel System data list-LB7 and LG4 only

Does the scan tool display the correct fuel level percentage?

--

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 sensors
         Refer to Testing for Intermittent Conditions and Poor Connections and to Connector Repairs in Wiring Systems.
    • A misaligned primary fuel level sender or secondary fuel level sender
    • A deformed primary fuel tank or secondary fuel tank

Did you find and correct the condition?

--

Go to Step 13

Go to Step 7

5

Test the signal circuits of the fuel level sensors for a high resistance. Refer to Circuit Testing and to 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 circuits of the fuel level sensors for a high resistance. Refer to Circuit Testing and to 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 senders.
  2. Inspect for the following items:
    3. • The fuel level sensors are stuck, perhaps due to an interference with the fuel strainer.
    • The fuel tanks contain foreign material, for instance, ice.

Did you find and correct the condition?

--

Go to Step 13

Go to Step 8

8
  1. With the J 39200 DMM, measure the resistance of each 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 for each fuel level sensor?

40-250 ohms (L18 and LB7) or 0-90 ohms (LG4 and LG5)

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 to 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 that did not respond correctly to the last inspection. Refer to:

    •  Fuel Sender Assembly Replacement in Engine Controls - 6.6L
    • Fuel Sender Assembly Replacement in Engine Controls - 7.8L
    •  Fuel Sender Assembly Replacement in Engine Controls - 8.1L

Did you complete the replacement?

--

Go to Step 13

--

11

Important: Program the replacement IPC.

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:

    •  Engine Control Module Replacement in Engine Controls - 6.6L
    •  Engine Control Module Replacement/Restore Fuel Rate Data in Engine Controls - 7.8L
    •  Powertrain Control Module Replacement in Engine Controls - 8.1L

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