GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2006 🢒 Malibu 🢒 Body 🢒 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 .
    • Refer to Fuel Level Specifications in order to verify the correct fuel level sender readings. The Fuel Tank Level Remaining parameter is available on the scan tool in the instrument panel cluster (IPC) powertrain control module (PCM) Data List or the IPC engine control module (ECM) Data List.

Test Description

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

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

    2.

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

Step

Action

Value(s)

Yes

No

Schematic Reference: Instrument Cluster Schematics

1

Did you perform the Diagnostic System Check - Vehicle?

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Go to Step 2

Go to Diagnostic System Check - Vehicle

2
  1. Disconnect C413 for the fuel systems.
  2. Connect the J 33431-C Signal Generator and Instrument Panel Tester between the signal circuit and the low reference circuit of the fuel level sensor on the male terminal side.
  3. Turn ON the ignition, 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 from 40-250 ohms.
  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?

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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 the ignition OFF 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 parameter in the IPC PCM Data List or the IPC ECM Data List.

Does the scan tool display the correct fuel level percent?

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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 .
    • A high resistance in the signal circuit or the low reference circuit between the fuel level sensor and C413
    • A misaligned fuel level sender
    • A deformed fuel tank

Did you find and correct the condition?

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Go to Step 13

Go to Step 7

5

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

Did you find and correct the condition?

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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 .

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. • A stuck fuel level sensor, i.e. the fuel strainer interfering with the sender float arm
    • Foreign material in the gas 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 powertrain control module (PCM)/engine control module (ECM). Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs .

Did you find and correct the condition?

--

Go to Step 13

Go to Step 12

10

Replace the fuel level sensor. Refer to Fuel Level Sensor Replacement for the 2.2L engine or Fuel Level Sensor Replacement for the 3.5L engine.

Did you complete the replacement?

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Go to Step 13

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11

Replace the instrument panel cluster (IPC). Refer to Control Module References for replacement, setup, and programming.

Did you complete the replacement?

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Go to Step 13

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12

Replace the PCM/ECM. Refer to Control Module References for replacement, setup, and programming.

Did you complete the replacement?

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Go to Step 13

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13

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

Did you correct the condition?

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System OK

Go to Step 2