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Home >> Chevrolet >> 1998 >> C3500 HD 6.5 F, Automatic >> Repair and Diagnosis >> Accessories & Equipment >> Gauges & Instrument Panels >> Testing & Diagnosis >> Fuel Gauge >> Fuel Gauge Inaccurate (Single Tank)

Fuel Gauge Inaccurate (Single Tank)

  1. Disconnect instrument cluster connector. Connect a fused jumper wire between instrument cluster connector terminal No. 22 (Pink wire) and battery voltage. See Figure. See WIRING DIAGRAMS. Connect another fused jumper wire between instrument cluster connector terminal No. 31 (Black/White wire) and ground. Connect one Red lead of Gauge Tester (J-33431-B) to instrument cluster connector terminal No. 16 (Purple wire). Connect other Red lead to ground.
  2. Set resistance dial to zero ohms. Fuel gauge should indicate empty or below. Set resistance dial to 90 ohms. After a short period, fuel gauge should indicate full or above. If fuel gauge responds as specified, go to next step. If fuel gauge does not respond as specified, replace instrument cluster.
  3. Remove fused jumper wires from instrument cluster connector and reconnect connector. Disconnect fuel pump/sender connector. Connect one Red lead of gauge tester to fuel pump/sender connector terminal "A" (Purple/White wire) on gasoline, or terminal "B" (Purple wire) on diesel. See WIRING DIAGRAMS . Connect other Red lead to ground. Set resistance dial to zero ohms, and then to 90 ohms. Fuel gauge should indicate empty, and then full. If fuel gauge responds as specified, go to step 5). If fuel gauge does not respond as specified, go to next step.
  4. Repair high resistance in Purple wire (gasoline) between instrument cluster and Vehicle Control Module (VCM), or Purple/White wire (gasoline) between VCM and fuel pump/sender; or in Purple wire (diesel) between instrument cluster and fuel pump/sender.
  5. Connect gauge between fuel pump/sender connector terminals "A" (Purple/White wire) and "D" (Black wire) on gasoline, or fuel pump/sender connector terminals "B" (Purple wire) and "A" (Black/White wire) on diesel. See WIRING DIAGRAMS . Set resistance dial to zero ohms, and then to 90 ohms. Fuel gauge should indicate empty, and then full. If fuel gauge responds as specified, replace fuel pump/sender. If fuel gauge does not respond as specified, repair high resistance in Black wire (gasoline), or Black/White wire (diesel) between fuel pump/sender and ground connection.
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