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Fuel Gauge Inaccurate Or Inoperative

NOTE: Corroded connections or severed ground paths generally cause fuel gauge to register past FULL position. Short circuits to ground generally result in fuel gauge resting below EMPTY position.
NOTE: After each repair procedure has been completed, reconnect all components. Perform INSTRUMENT PANEL CLUSTER (IPC) SYSTEM CHECK  under SYSTEM TESTS.
  1. Perform INSTRUMENT PANEL CLUSTER (IPC) SYSTEM CHECK  under SYSTEM TESTS. Go to next step.
  2. Turn ignition switch to OFF position. Disconnect 6-pin chassis-to-engine in-line harness connector, located under vehicle, leading to fuel tank. Connect Signal Generator and Instrument Panel Tester (J33431-C) between male terminal side of connector terminal "E" (Purple wire) and terminal "D" (Orange/Black wire on 2.2L engines, Black wire on 4.3L engines). See Fig 1 . Turn ignition switch to ON position. Vary resistance on J33431-C while observing fuel gauge on IPC. When resistance is near 40 ohms, fuel gauge should read EMPTY. When resistance is near 250 ohms, fuel gauge should read FULL. If operation is as specified, go to step  4 . If resistance is not as specified, go to next step.
  3. Turn ignition switch to OFF position. Connect scan tool to DLC. Turn ignition switch to ON position. Vary resistance on J33431-C while observing FUEL TANK LEVEL REMAINING parameter in PCM data list. See FUEL TANK LEVEL SPECIFICATIONS  table. If FUEL TANK LEVEL REMAINING parameter is according to specification, go to step  11 . If parameter is not as specified, go to step  5 .
  4. Check for poor connection at fuel level sensor harness connector. Check for high resistance in Purple wire and Orange/Black wire (2.2L) or Black wire (4.3L) between 6-pin chassis-to-engine in-line harness connector and fuel level sensor. Check for a misaligned fuel level sensor. Check for a damaged/deformed fuel tank. Repair as necessary. If problem was found and repaired, go to step  13 . If problem was not found, go to step  7 .
  5. Check for high resistance in Purple wire between 6-pin chassis-to-engine in-line harness connector and PCM. See WIRING DIAGRAMS  . Repair wiring as necessary, then go to step  13 . If no problems are found, go to next step.
  6. Check for high resistance in Orange/Black wire (2.2L) or Black wire (4.3L) between 6-pin chassis-to-engine in-line harness connector and PCM. See WIRING DIAGRAMS  . Repair wiring as necessary, then go to step  13 . If no problems are found, go to step  9 .
  7. Remove fuel level sensor. See FUEL PUMP under FUEL SYSTEM (GASOLINE) in REMOVAL, OVERHAUL & INSTALLATION - TRUCKS article in ENGINE PERFORMANCE. Check fuel level sensor for mechanical fault, damaged level arm or for fuel strainer interfering with level arm. Check fuel tank for foreign material. Repair as necessary, then go to step  13 . If no problems are found, go to next step.
  8. Connect DVOM between fuel level sensor terminal "A" (Purple wire) and terminal "D" (Orange/Black wire on 2.2L, Black/White wire on 4.3L). Monitor resistance while moving level arm. If resistance changes smoothly (40-250 ohms) as arm is moved, system is functioning properly at this time. Check connections and wiring for intermittent faults. See WIRING DIAGRAMS  . If resistance does not vary smoothly as level arm is moved, go to step  10 .
  9. Check PCM connector for poor connection or corroded terminals. Repair connector as necessary, then go to step  13 . If no problems are found, go to step  12 .
  10. Replace fuel level sensor. See FUEL PUMP under FUEL SYSTEM (GASOLINE) in REMOVAL, OVERHAUL & INSTALLATION - TRUCKS article in ENGINE PERFORMANCE. When repair is complete, go to step  13 .
  11. Replace IPC. See INSTRUMENT PANEL CLUSTER  under REMOVAL & INSTALLATION. When repair is complete, go to step  13 .
  12. Replace PCM. See POWERTRAIN CONTROL MODULE under COMPUTERIZED ENGINE CONTROLS in REMOVAL, OVERHAUL & INSTALLATION - TRUCKS article in ENGINE PERFORMANCE. When repair is complete, go to next step.
  13. Using scan tool, clear PCM DTCs. Operate vehicle to verify proper fuel gauge operation. If fuel gauge operation is normal, repair is complete. If fuel gauge operation is faulty, go to step  2 .
Fig 1: Identifying Connector C104 Terminals
G00061857Courtesy of GENERAL MOTORS CORP.
FUEL TANK LEVEL SPECIFICATIONS

Application Resistance (Ohms) Fuel Remaining Percentage
18 Gallon Tank (4-Door Utility) 48-63 2-15
88-99 33-38
122-132 53-58
155-165 68-78
210-235 90-95
19 Gallon Tank (2-Door Utility 55-60 11-16
98-103 35-40
130-135 55-60
174-179 77-82
200-235 90-100
18.5 Gallon Tank (Pickup) 48-63 11-16
82-86 35-40
122-126 55-60
164-168 77-82
226-230 90-100
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