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Home >> Chevrolet >> 2004 >> Malibu Base >> Repair and Diagnosis >> Accessories & Equipment >> Gauges & Instrument Panels >> Instrument Panel System Displays, Gauges And Console >> Diagnostic Information and Procedures >> Fuel Gage Inaccurate or Inoperative >> Test Description

Test Description

The numbers below refer to the step numbers in the diagnostic table.

  1. 3:  This step tests for a high resistance in the signal circuit and the low reference circuit of the fuel level sender.
  2. 13:  DTCs will be set in the powertrain control module (PCM) when you perform this diagnostic table.
FUEL GAGE INACCURATE OR INOPERATIVE

Step Action Value(s) Yes No
Schematic Reference: Instrument Cluster Schematics 
1 Did you perform the Diagnostic System Check - Vehicle? - Go to Step 2  Go to Diagnostic System Check - Vehicle in Vehicle DTC Information
2
  1. Disconnect C400 for the fuel systems.
  2. Connect the J 33431-C  Signal Generator and Instrument Panel Tester between the signal circuit and the low reference circuit of the fuel level sensor on the male terminal side. See Special Tools and Equipment .
  3. Turn the ignition ON, with the engine OFF.
    4. IMPORTANT: Verify the J 33431-C  resistance settings with a DMM. See Special Tools and Equipment .
  4. Vary the resistance on the J 33431-C  from 40-250 ohms. See Special Tools and Equipment .
  5. Refer to Fuel Level Specifications (Sedan)  and Fuel Level Specifications (Extended Sedan)  in order to convert from resistance to fuel gage display.
Does the fuel gage display the correct fuel level?		 - Go to Step 4  Go to Step 3 
3 
  1. Install a scan tool.
  2. Turn the ignition ON, with the engine OFF.
    3. IMPORTANT: Verify the J 33431-C  resistance settings with a DMM. See Special Tools and Equipment .
  3. Vary the resistance on the J 33431-C  from 40-250 ohms. See Special Tools and Equipment .
  4. Refer to Fuel Level Specifications (Sedan)  and Fuel Level Specifications (Extended Sedan)  in order to convert from resistance to fuel level percent.
    5. IMPORTANT: Turn the ignition OFF momentarily between the resistance settings in order to quickly update the scan tool display.
  5. With the scan tool, observe the Fuel Tank Level Remaining parameter in the IPC PCM Data list.
Does the scan tool display the correct fuel level percent?		 - Go to Step 11  Go to Step 5 
4 Inspect for the following items:
Did you find and correct the condition?		 - Go to Step 13  Go to Step 7 
5 Test the fuel level sensor signal circuit for a high resistance. Refer to Circuit Testing and to Wiring Repairs in Wiring Systems.
Did you find and correct the condition?		 - Go to Step 13  Go to Step 6 
6 Test the low reference circuit of the fuel level sensor for a high resistance. Refer to Circuit Testing and to Wiring Repairs in Wiring Systems.
Did you find and correct the condition?		 - Go to Step 13  Go to Step 9 
7
  1. Remove the fuel level sender.
  2. Inspect for the following items:
    • A stuck fuel level sensor, i.e. the fuel strainer interfering with the sender float arm
    • Foreign material in the gas tank, ice
Did you find and correct the condition?		 - Go to Step 13  Go to Step 8 
8
  1. With the J 39200  DMM, measure the resistance of the fuel level sensor while moving the float arm.
  2. Observe both the analog and digital displays on the DMM.
Does the resistance change smoothly across the specified range?		 40-250 Ω Go to Diagnostic Aids Go to Step 10 
9 Inspect for poor connections at the harness connector of the powertrain control module (PCM). Refer to Testing for Intermittent Conditions and Poor Connections and to Connector Repairs in Wiring Systems.
Did you find and correct the condition?		 - Go to Step 13  Go to Step 12 
10 Replace the fuel level sensor. Refer to Fuel Level Sensor Replacement (Malibu Sedan)Fuel Level Sensor Replacement (Malibu MAXX) in Engine Controls - 2.2L or Fuel Level Sensor Replacement (Malibu Sedan) and Fuel Level Sensor Replacement (Malibu MAXX) in Engine Controls - 3.5L.
Did you complete the replacement?		 - Go to Step 13  -
11 Replace the instrument panel cluster (IPC). Refer to Instrument Panel Cluster (IPC) Replacement .
Did you complete the replacement?		 - Go to Step 13  -
12 Replace the powertrain control module (PCM). Refer to Powertrain Control Module (PCM) Replacement in Engine Controls - 2.2L or to Powertrain Control Module (PCM) Replacement in Engine Controls - 3.5L.
Did you complete the replacement?		 - Go to Step 13  -
13 
  1. Use a scan tool in order to clear the PCM DTCs.
  2. Operate the system in order to verify the repair.
Did you correct the condition?		 - System OK Go to Step 2 
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