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Test K: Fuel Gauge Inoperative Or Inaccurate: Notes

WARNING: This page is about a different car, the 2002 Chevrolet Monte Carlo, 2002 Chevrolet Impala, 2001 Chevrolet Monte Carlo, and 2001 Chevrolet Impala. However, it is still accessible from the selected car via links, so may be relevant.
  1. Perform instrument panel cluster system diagnostic system check. See INSTRUMENT PANEL CLUSTER SYSTEM DIAGNOSTIC SYSTEM CHECK  under SELF-DIAGNOSTIC SYSTEM. If instrument panel cluster system diagnostic system check has been performed, go to next step.
  2. Disconnect 4-pin fuel level sensor connector, located below access panel in trunk. Connect Signal Generator and Instrument Panel Tester (J33431-C) between fuel level sensor harness connector terminals "A" (Purple wire) and "D" (Black/White wire). Turn ignition switch to RUN position. Vary resistance between 40 ohms and 250 ohms on tester, and observe fuel gauge. See FUEL LEVEL SPECIFICATIONS  table. If fuel gauge indication does not agree with selected resistances, go to next step. If fuel gauge indication agrees with selected resistances, go to step  4 .
  3. Turn ignition off. Connect scan tool to Data Link Connector (DLC). Turn ignition switch to RUN position. Vary resistance between 40 ohms and 250 ohms on tester, and observe scan tool fuel level percentage reading. See FUEL LEVEL SPECIFICATIONS  table. If scan tool does not display correct fuel level percentages, go to step  5 . If scan tool displays corrects fuel level percentages, go to step  11 . Also using scan tool observe FUEL TANK LEVEL REMAINING (%) parameter in PCM EVAP data list. Compare scan tool parameter with fuel tank level remaining specifications. See FUEL LEVEL SPECIFICATIONS  table. If scan tool does not display correct fuel tank level remaining percentages, go to step  5 . If scan tool displays corrects fuel tank level remaining percentages, go to step  11 .
  4. Check for poor connection at fuel level sensor, misaligned fuel level sensor float and/or deformed fuel tank. Repair or replace as necessary and go to step  13 . If no problems were found, go to  7 .
  5. Check for high resistance in Purple wire between PCM Clear 80-pin connector C2 terminal No. 69 and fuel level sensor connector terminal "A". See Figure . Repair as necessary and go to step  13 . See WIRING DIAGRAMS  . If wire is okay, go to next step.
  6. Check for high resistance in circuit between PCM Clear 80-pin connector C2 terminal No. 35 (Black wire) and fuel level sensor connector terminal "D" (Black/White wire). Repair as necessary and go to step  13 . See WIRING DIAGRAMS  . If circuit is okay go to step  9 .
    7. NOTE: Fuel level sensor is part of fuel pump and sender assembly.
  7. Remove fuel level sensor from fuel tank. See FUEL PUMP under FUEL SYSTEM in appropriate REMOVAL, OVERHAUL & INSTALLATION article in ENGINE PERFORMANCE. Inspect for obstruction to fuel level sensor float arm, faulty float or foreign material in tank. Repair or replace as necessary and go to step  13 . If no problem is found, go to next step.
  8. Measure resistance between fuel level sensor connector terminals "A" (Purple wire) and "D" (Black/White wire) while moving float arm through full travel. If resistances vary smoothly between 40 ohms and 250 ohms, go to DIAGNOSTIC AIDS  . If resistances does not vary smoothly between 40 ohms and 250 ohms, go to step  10 .
  9. Disconnect PCM Clear 80-pin connector C2. Check for poor connection at PCM Clear 80-pin harness connector C2. Repair as necessary and go to step  13 . If connection is okay, go to step  12 .
    10. NOTE: Fuel level sensor is part of fuel pump and sender assembly.
  10. Replace fuel level sensor. See FUEL PUMP under FUEL SYSTEM in appropriate REMOVAL, OVERHAUL & INSTALLATION article in ENGINE PERFORMANCE. After repair, go to step  13 .
  11. Replace IPC. See INSTRUMENT PANEL CLUSTER (IPC)  under REMOVAL & INSTALLATION. After repair, go to step  13 .
  12. Replace and reprogram PCM. See BODY CONTROL MODULES - IMPALA & MONTE CARLO article. After repair, go to next step.
  13. Using scan tool, clean all PCM DTCs. Operate vehicle to verify repairs. If no problem is found, repairs are complete. If condition still exists, return to step  2 .
FUEL LEVEL SPECIFICATIONS

Fuel Gauge Indication Ohms Fuel Level Fuel Remaining - Gal (L)
Empty 40-62 0-9% 0-1.3 (0-4.9)
1/4 95 29% 4.9 (18.5)
1/2 125 49% 8.4 (31.8)
3/4 156 70% 11.9 (45.0)
Full 200-230 90-100% 15.4-17.0 (58.3-64.3)
Low Fuel Indicator On 69 13% 2.2 (8.3)
Low Fuel Indicator Off 87 23% 4.0 (15.1)
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