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Test No. 2: Fuel Gauge Inaccurate/Inoperative: Testing

  1. If instrument panel cluster diagnostic system check has been performed, go to next step. If instrument panel cluster diagnostic system check has not been performed, go to INSTRUMENT PANEL CLUSTER DIAGNOSTIC SYSTEM CHECK  under SELF-DIAGNOSTIC SYSTEM.
  2. Turn ignition off. Disconnect fuel level sender assembly. See COMPONENT LOCATIONS  . Connect gauge tester (J33431-C) between fuel level sender connector terminals "D" (Purple/White wire) and "F" (Black wire). Turn ignition on. Vary resistance between 40-72 ohms (empty) and 234-250 ohms (full). If fuel gauge does not display correct level, go to next step. If fuel gauge displays correct level, go to step  4 .
  3. Turn ignition off. Connect scan tool to Data Link Connector (DLC). Turn ignition on. Select Platform Zone Module (PZM) data list. Monitor FUEL LEVEL % parameter. Vary resistance between 40-72 ohms (empty) and 234-250 ohms (full). Check readings on scan tool with specifications. See FUEL LEVEL SPECIFICATIONS  table. If FUEL LEVEL % parameter is not within specification, go to next step. If FUEL LEVEL % parameter is within specification, go to step  11 .
  4. Check for poor connections at fuel level sender connector. Remove fuel level sender. See FUEL LEVEL SENSOR  under REMOVAL & INSTALLATION. Check for misaligned fuel sensor or deformed fuel tank. If fault is not found, go to step  7 . If fault is found, repair as necessary and go to step  13 .
  5. Check for high resistance in Purple/White wire between Platform Zone Module (PZM) connector C1 terminal B12 and fuel level sender connector terminal "D". See Figure . If circuit is okay, go to next step. If faulty circuit is found and repaired, go to step  13 .
  6. Check for high resistance in Black wire between Platform Zone Module (PZM) connector C1 terminal B11 and fuel level sender connector terminal "F". If circuit is okay, go to step  9 . If faulty circuit is found and repaired, go to step  13 .
  7. With fuel level sender removed, check for stuck fuel level sender or foreign material in fuel tank. If fault is not found, go to next step. If fault is found, repair as necessary and go to step  13 .
  8. With fuel level sender removed, using DVOM, measure resistance between fuel level sender connector terminals "D" (Purple wire) and "F" (Black wire). Monitor DVOM and manually move fuel level float arm up and down. If resistance changes smoothly between 40-250 ohms, go to DIAGNOSTIC AIDS  . If resistance does not change smoothly between 40-250 ohms, go to step  10 .
  9. Check for poor connections at PZM connector terminals. If connections are okay, go to step  12 . If faulty connections are found and repaired, go to step  13 .
  10. Replace fuel level sensor. See FUEL LEVEL SENSOR  under REMOVAL & INSTALLATION. After repairs, go to step  13 .
  11. Replace Instrument Panel Cluster (IPC). See INSTRUMENT PANEL CLUSTER (IPC)  under REMOVAL & INSTALLATION. Using scan tool, obtain approximate mileage, and contact an authorized Delco service center for transfer of information from failed IPC to replacement IPC. After repairs, go to step  13 .
  12. Replace PZM. See REMOVAL & INSTALLATION in BODY CONTROL MODULES - ELDORADO article. After repairs, go to next step.
  13. Use scan tool to clear any DTCs. Recheck operation of fuel gauge. If gauge operates properly, repair is complete. If fuel gauge does not operate properly, go to step  2 .
FUEL LEVEL SPECIFICATIONS

Gauge Reading Tester Resistance (Ohms) Scan Tool Display (%) Amount of Fuel (Gallons)
E 40-72 0-10 0-2
1/4 128 32 6
1/2 168 54 10
3/4 206 75 14
F 234-250 91-100 17.0-18.5
Low Fuel Indicator On 94 16 3
Low Fuel Indicator Off 100 18 3.5
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