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Test D: Fuel Gauge Inaccurate Or Inoperative (Gasoline): Notes

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2001 GMC Savana Special, 2001 GMC Savana Camper Special, 2001 GMC Savana, 2001 Chevrolet RV Cutaway, and 2001 Chevrolet Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Verify fuel level is in same range as customer concern.
  1. If Instrument Panel Cluster (IPC) diagnostic system check has been performed, go to next step. If IPC diagnostic system check has not been performed, go to INSTRUMENT PANEL CLUSTER DIAGNOSTIC SYSTEM CHECK  .
  2. Disconnect in-line Black 7-pin harness connector C301. Connect Signal Generator And Instrument Panel Tester (J-33431-C) between female side of in-line connector C301 terminals "B" (Purple wire) and "C" (Black wire) (except RPO Code NB6; tier 1 California emission system) or "F" (Black wire) (with RPO Code NB6; tier 1 California emission system). See Figure . Turn ignition switch to RUN position. Using a DVOM to verify signal generator and instrument panel tester resistance settings, vary tester resistance settings from 40-250 ohms. See FUEL LEVEL SPECIFICATIONS  table. If fuel gauge does not display the correct fuel level, go to next step. If fuel gauge displays the correct fuel level, go to step  4 .
    FUEL LEVEL SPECIFICATIONS

    Fuel Gauge Level Resistance - Ohms Fuel Tank Level - Percent
    31 Gallon Tank
    Full 232 86
    3/4 165 60
    1/2 135 46
    1/4 110 35
    Empty 51 8
    35 Gallon Tank
    Full 226 90
    3/4 183 65
    1/2 145 45
    1/4 117 31
    Empty 48 8
    55 Gallon Tank
    Full 250 85-89
    3/4 232 79-83
    1/2 203 63-68
    1/4 161 23-27
    Empty 85 0-5
  3. Turn ignition switch to OFF position. Connect scan tool to Data Link Connector (DLC), located below steering column. See Figure . Turn ignition switch to RUN position. Vary tester resistance settings from 40-250 ohms. See FUEL LEVEL SPECIFICATIONS  table. Momentarily turn ignition switch to OFF position between each resistance setting to quickly update scan tool display. Monitor scan tool display FUEL LEVEL REMAINING parameter in PCM EVAP data display. If fuel level remaining parameter does not display the correct fuel level percentage, go to step  5 . If fuel level remaining parameter displays the correct fuel level percentage, go to step  10 .
  4. Check for high resistance in Black wire between in-line connector C301 terminal "C" (Black wire) (without tier 1 California emission system) or "F" (Black wire) (with tier 1 California emission system) and fuel pump and level sender harness connector terminal "D". See Figure . Check for fuel pump and level sender connector for intermittent or poor terminal contact. Check for a misaligned fuel level sender and/or deformed fuel tank. If Black wire, terminal contact, fuel level sender alignment or fuel tank are not okay, go to step  7 . If Black wire, terminal contact, fuel level sender alignment and fuel tank are okay, go to step  15 .
  5. Check for high resistance in Purple wire (signal circuit) between fuel pump and level sensor harness connector terminal "A" and PCM harness connector C2 terminal No. 54. See Figure and Figure . If Purple wire is okay, go to next step. If Purple wire is not okay, repair as necessary. After repair, go to step  15 .
  6. Check for high resistance in Black wire (low reference circuit) between fuel tank and level sensor harness connector terminal "D" and PCM harness connector C1 terminal No. 23. See Figure and Figure . If Purple wire is okay, go to next step. If Purple wire is not okay, repair as necessary. After repair, go to step  15 .
  7. Remove fuel level sender. Check level sensor for binding, sticking or for any interference. Check fuel tank for foreign material. If fuel level sender and tank are okay, go to next step. If fuel level sender and/or tank are not okay, repair as necessary. After repair, go to step  15 .
  8. Using DVOM in analog and digital displays, measure fuel level sender resistance while moving float arm. If resistance varied smoothly from 40-250 ohms, go to DIAGNOSTIC AIDS  . If resistance does not vary smoothly from 40-250 ohms, go to step  13 .
  9. Check PCM connectors for intermittent or poor terminal contact. If terminal contact is okay, go to step  14 . If terminal contact is not okay, repair as necessary. After repair, go to step  15 .
  10. Check for high resistance in Purple wire (signal circuit to IPC) between PCM harness connector C2 terminal No. 32 and IPC harness connector terminal B2. See Figure and Figure . If Purple wire is okay, go to next step. If Purple wire is not okay, repair as necessary. After repair, go to step  15 .
  11. Check IPC connector for intermittent or poor terminal contact. If terminal contact is okay, go to next step. If terminal contact is not okay, repair as necessary. After repair, go to step  15 .
  12. Replace IPC. After repair, go to step  15 .
  13. Replace fuel level sender. After repair, go to step  15 .
  14. Replace PCM. Program as necessary. See PROGRAMMING  . After repair, go to next step.
  15. Using scan tool, clear DTCs. Operate system to verify fault no longer exists. If fault still exists, go to step  2 .
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