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Test E: Fuel Gauge Inaccurate Or Inoperative (Diesel)

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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 C301 terminal. Connect the J 33431-C Signal Generator and Instrument Panel Tester between the signal circuit and low reference circuit of the fuel level sensor on female terminal side of the connector. Turn ignition to RUN position. Vary the resistance on the J 33431-C from 40-250 ohms. If fuel gauge displays correct fuel level, go to next step. If gauge does not display correct fuel level, go to step  4 .
  3. Inspect for high resistance in the signal circuit or the low reference circuit of the fuel level sensor between C301 and fuel level sensor, and poor connection at the harness connector of the fuel level sensor. If condition is found, repair as necessary and go to step  20 . If no condition is found, go to step  5 .
  4. Test for an open, high resistance, or a short to ground. If condition is found, repair as necessary and go to step  20 . If no condition is found, go to step  6 .
  5. Remove fuel level sender. Inspect for fuel level sensor to be stuck due to an interference with the strainer and fuel tank to contain foreign material like ice. If condition is found, repair as necessary and go to step  20 . If no condition is found, go to step  11 .
  6. Test low reference circuit of fuel level sensor for an open or high resistance. If condition is found, repair as necessary and go to step  20 . If no condition is found, go to next step.
  7. Test fuel level sender buffer module for an open, high resistance, or a short to ground. If condition is found, repair as necessary and go to step  20 . If no condition is found, go to next step.
  8. Measure voltage between instrument cluster and fuel sender buffer module. If voltage measures greater than 8.0V, go to next step. If voltage measures less than 8.0V, go to step  12 .
  9. Disconnect fuel sender buffer module. Measure the voltage at the passlock 5 volt reference circuit. If voltage measures 5.0V, go to step  16 . If voltage does not measure 5.0V, go to next step.
  10. Test Passlock module 5 volt reference circuit for an open, high resistance, or a short to ground. If condition is found, repair as necessary and go to step  20 . If no condition is found, go to step  15 .
  11. Measure the resistance of the fuel level sensor while moving the float arm. Observe the analog and digital displays on the DMM. If resistance changes smoothly between 40-250 ohms, verify that the fuel level is in the same range as the customer concern.. If resistance does not change smoothly between 40-250 ohms, go to step  18 .
  12. Test the ground circuit of the fuel sender buffer module for an open or a high resistance. If condition is found, repair as necessary and go to step  20 . If no condition is found, go to next step.
  13. Test the fuel level signal circuit to the instrument cluster for an open, high resistance, or short to ground. If condition is found, repair as necessary and go to step  20 . If no condition is found, go to next step.
  14. Inspect the harness connector of the instrument panel cluster (IPC) for poor connections. If poor connection is found, repair as necessary and go to step  20 . If poor connection is not found, go to step  17 .
  15. Inspect harness connector of the passlock module for poor connections. If poor connection is found, repair as necessary and go to step  20 . If poor connection is not found, go to step  19 .
  16. Replace fuel sender buffer module, then go to step  20 .
  17. Replace the instrument panel cluster (IPC), then go to step  20 .
  18. Replace fuel level sender, then go to step  20 .
  19. Replace the passlock module, then go to next step.
  20. Operate system to verify the repair. If condition is not corrected, go to step  2 .
Fig 1: Identifying Passlock(tm) Module Harness Connector Terminals
G00062259Courtesy of GENERAL MOTORS CORP.
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