GM Service Manual Online
For 1990-2009 cars only

Fuel Gauge Always Indicates Full Gas

Step

Action

Value(s)

Yes

No

Important:: Before performing the diagnostics below, perform a diagnostic circuit check and repair DTC's P0461, P0462, or P0463 pertaining to the fuel tank senders.

1

Did you perform the Instrument Cluster System Check?

--

Go to Step 2

Go to Instrument Cluster System Check

2

  1. Remove the IP Cluster.
  2. Disconnect the Vehicle Control Module (VCM) connector C1.
  3. Connect a DMM (ohms) between cavity 9 of VCM connector C1 and cavity 16 of the IP Cluster.

Is the resistance greater than the value given?

0.5ohms

Go to Step 3

Go to Step 4

3

Locate and repair the open or cause of resistance in CKT 30 (PPL) between VCM connector C1 and the IP Cluster. Refer to Wiring Repairs in Wiring Systems.

Is the repair complete?

--

Go to Instrument Cluster System Check

--

4

Replace the I/P Cluster. Refer to Instrument Cluster Replacement .

Is the repair complete?

--

Go to Instrument Cluster System Check

--

Fuel Gauge Always Indicates Full Dual Tank Diesel

Step

Action

Value(s)

Yes

No

1

Did you perform the Instrument Cluster System Check?

--

Go to Step 2

Go to Instrument Cluster System Check

2

  1. Disconnect the Fuel Pump and Balance Module connector.
  2. Connect a jumper wire between cavity F of the Fuel Pump and Balance Module connector and ground.
  3. Turn the ignition switch to the RUN position.

Does the fuel gauge go to Empty?

--

Go to Step 6

Go to Step 3

3

  1. Disconnect the I/P Cluster.
  2. Connect a J 39200 DMM (continuity) between cavity F of the Fuel Pump and Balance Module connector and pin 16 of the I/P Cluster.

Is continuity present?

--

Go to Step 4

Go to Step 5

4

Replace the I/P Cluster. Refer to Instrument Cluster Replacement .

Is the repair complete?

--

Go to Instrument Cluster System Check

--

5

Locate and repair the open in CKT 30 (PPL) between the Fuel Pump Balance Module and the I/P Cluster. Refer to Wiring Repairs in Wiring Systems.

Is the repair complete?

--

Go to Instrument Cluster System Check

--

6

Connect a J 39200 DMM (continuity) between cavity E of the Fuel Pump and Balance Module connector and ground.

Is continuity present?

--

Go to Step 7

Go to Step 13

7

Connect a J 39200 DMM (ohms) between cavities B and E of the Fuel Pump and Balance Module connector.

Does the reading indicate the value given?

0ohms Empty/90ohms Full

Go to Step 14

Go to Step 8

8

  1. Disconnect the Secondary Fuel Gauge Sender.
  2. Connect a J 39200 DMM (ohms) between the senders two pins.

Does the reading indicate the value given?

0ohms Empty/90ohms Full

Go to Step 10

Go to Step 9

9

Replace the Secondary Fuel Gauge Sender.

Is the repair complete?

--

Go to Instrument Cluster System Check

--

10

Connect a J 39200 DMM (continuity) between cavity E of the Fuel Pump and Balance Module connector and cavity A of the Secondary Fuel Gauge Sender.

Is continuity present?

--

Go to Step 11

Go to Step 12

11

Locate and repair the open in CKT 975 (LT BLU) between the Fuel Pump and Balance Module and the Secondary Fuel Gauge Sender. Refer to Wiring Repairs in Wiring Systems.

Is the repair complete?

--

Go to Instrument Cluster System Check

--

12

Locate and repair the open in CKT 451 (BLK/WHT) between the Secondary Fuel Gauge Sender and G104. Refer to Wiring Repairs in Wiring Systems.

Is the repair complete?

--

Go to Instrument Cluster System Check

--

13

Locate and repair the open in CKT 451 (BLK/WHT) between the Fuel Pump and Balance Module and G104. Refer to Wiring Repairs in Wiring Systems.

Is the repair complete?

--

Go to Instrument Cluster System Check

--

14

Connect a J 39200 DMM (ohms) between cavities C and E of the Fuel Pump and Balance Module connector.

Does the reading indicate the value given?

0ohms Empty/90ohms Full

Go to Step 20

Go to Step 15

15

  1. Disconnect the Primary Fuel Gauge Sender.
  2. Connect a J 39200 DMM (ohms) between the senders two pins.

Does the reading indicate the value given?

0ohms "Empty"/90ohms "Full"

Go to Step 16

Go to Step 19

16

Connect a J 39200 DMM (continuity) between cavity E of the Fuel Pump and Balance Module connector and cavity A of the Primary Fuel Gauge Sender.

Is continuity present?

--

Go to Step 17

Go to Step 18

17

Locate and repair the open in CKT 970 (DK BLU/WHT) between the Fuel Pump and Balance Module and the Primary Fuel Gauge Sender. Refer to Wiring Repairs in Wiring Systems.

Is the repair complete?

--

Go to Instrument Cluster System Check

--

18

Locate and repair the open in CKT 451 (BLK/WHT) between the Primary Fuel Gauge Sender and G104. Refer to Wiring Repairs in Wiring Systems.

Is the repair complete?

--

Go to Instrument Cluster System Check

--

19

Replace the Primary Fuel Gauge Sender. Refer to Fuel Sender Assembly Replacement in Engine Controls.

Is the repair complete?

--

Go to Instrument Cluster System Check

--

20

Replace the Fuel Pump and Balance Module.

Is the repair complete?

--

Go to Instrument Cluster System Check

--

Fuel Gauge Always Indicates Full Single Tank, Diesel

Step

Action

Value(s)

Yes

No

1

Did you perform the Instrument Cluster System Check?

--

Go to Step 2

Go to Instrument Cluster System Check

2

  1. Disconnect the Fuel Pump and Sender connect at the left side frame rail.
  2. Connect a jumper wire on CKT 30 (PPL) between pin B of the Fuel Pump and Sender connector and ground.
  3. Turn the ignition switch to the RUN position.

Does the fuel gauge read empty?

--

Go to Step 6

Go to Step 3

3

Connect a J 39200 DMM (ohms) between cavities A & B of the Fuel Pump and Sender.

Does the resistance read according to the fuel level?

0 ohms Empty/90 ohms Full

Go to Step 4

Go to Step 6

4

  1. Connect the Fuel Pump and Sender connector.
  2. Remove the I/P Cluster. Refer to Instrument Cluster Replacement
  3. Connect a J 39200 DMM between pin 16 of the I/P Cluster connector and ground.

Does the resistance read according to fuel level?

0 ohms Empty/90 ohms Full

Go to Step 5

Go to Step 7

5

Replace the I/P Cluster. Refer to Instrument Cluster Replacement

Is the repair complete?

--

Go to Instrument Cluster System Check

--

6

Replace the Fuel Pump and Sender. Refer to Fuel Sender Assembly Replacement in Engine Controls.

Is the repair complete?

--

Go to Instrument Cluster System Check

--

7

Locate and repair the open in CKT 30 (PPL) between the I/P Cluster and Fuel Pump and Sender. Refer to Wiring Repairs in Wiring Systems.

Is the repair complete?

--

Go to Instrument Cluster System Check

--