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Fuel Gauge Is Inaccurate (Diesel Engine)

  1. With known amount of fuel in tank, check gauge readings. If gauge reads significantly different than known amount, go to next step. If gauge is reasonably accurate, system is okay.
  2. Disconnect fuel tank level sender harness connector. Turn ignition switch to RUN position. Using Tester (J-33431-B), connect tester leads between Purple and Black wire terminals of harness connector. Set dial to 40 ohms. Slowly rotate dial to 250 ohms. If fuel gauge reads EMPTY, then FULL, replace fuel tank level sender. If gauge does not respond as specified, go to next step.
  3. Turn ignition switch to OFF position. Disconnect Passlock(tm) module harness connector. Connect fused jumper wire between Passlock(tm) module harness connector terminal B1 (Black/White wire) and ground. See Figure . Turn ignition switch to RUN position. Using Tester (J-33431-B), set dial to 40 ohms. Slowly rotate dial to 250 ohms. If fuel gauge reads EMPTY, then FULL, repair open in Black/White. If gauge does not respond as specified, go to next step.
  4. Remove jumper wire. Connect fused jumper wire between Passlock(tm) module harness connector terminal B5 (Orange/Black wire) and ground. Using Tester (J-33431-B), set dial to 40 ohms. Slowly rotate dial to 250 ohms. If fuel gauge reads EMPTY, then FULL, problem is in theft deterrent system. See ANTI-THEFT SYSTEMS - EXPRESS, ESCALADE, PICKUP, SAVANA, TAHOE & YUKON DENALI article. If gauge does not respond as specified, go to next step.
  5. Disconnect tester lead from Black wire at fuel tank level sender connector. Reconnect tester lead to ground. Set dial to 40 ohms. Slowly rotate dial to 250 ohms. If fuel gauge reads EMPTY, then FULL, repair open in Black wire between fuel tank level sender and Passlock(tm) module. If gauge does not respond as specified, go to next step.
  6. Turn ignition switch to OFF position. Reconnect Passlock(tm) module harness connector and fuel tank level sender harness connector. Disconnect fuel sender buffer module harness connector. Using Tester (J-33431-B), connect tester leads between fuel sender buffer module harness connector terminal "L" (Purple wire) and ground. See Figure . Turn ignition switch to RUN position. Set dial to 40 ohms. Slowly rotate dial to 250 ohms. If fuel gauge reads EMPTY, then FULL, go to next step. If gauge does not respond as specified, go to step  11 .
  7. Using voltmeter connected to ground, backprobe fuel sender buffer module harness connector terminal "A" (Pink wire). If voltage is more than 10 volts, go to next step. If voltage is less than 10 volts, repair open in Pink wire.
  8. Using voltmeter connected to ground, backprobe fuel sender buffer module harness connector terminal "B" (Gray wire). If voltage is 4.5-5.5 volts, go to step  10 . If voltage is not 4.5-5.5 volts, go to next step.
  9. Using voltmeter connected to ground, backprobe Passlock(tm) module harness connector terminal B6 (Gray wire). See Figure . If voltage is 4.5-5.5 volts, repair open in Gray wire. If voltage is not 4.5-5.5 volts, problem is in theft deterrent system. See ANTI-THEFT SYSTEMS - EXPRESS, ESCALADE, PICKUP, SAVANA, TAHOE & YUKON DENALI article.
  10. Disconnect Passlock(tm) module harness connector. Using ohmmeter, measure resistance between Passlock(tm) module harness connector terminal "M" (Black/White wire) and ground. If resistance is less than 5 ohms, replace fuel sender buffer module. If resistance is more than 5 ohms, repair open in Black/White wire.
  11. Reconnect all disconnected components. Disconnect instrument cluster harness connector. Connect a fused jumper wire between instrument cluster harness connector terminal B17 (Pink wire) and instrument cluster (component side) terminal B17. Connect second fused jumper wire between instrument cluster harness connector terminal B13 (Black wire) and instrument cluster (component side) connector terminal B13. Using Tester (J-33431-B), connect Red tester lead to instrument cluster (component side) terminal B2 (Purple wire) and Black lead to ground. Set dial to 40 ohms. Slowly rotate dial to 250 ohms. If fuel gauge reads EMPTY, then FULL, repair open in Purple wire. If gauge does not respond as specified, go to next step.
  12. Connect a fused jumper wire between instrument cluster harness connector terminal B17 (Pink wire) and battery power. Connect second fused jumper wire between instrument cluster harness connector terminal B13 (Black wire) and instrument cluster (component side) terminal B13. Using Tester (J-33431-B), connect Red tester lead to instrument cluster (component side) terminal B2 (Purple wire) and Black lead to ground. Set dial to 40 ohms. Slowly rotate dial to 250 ohms. If fuel gauge reads EMPTY, then FULL, repair open in Pink wire. If gauge does not respond as specified, go to next step.
  13. Using ohmmeter, measure resistance between instrument cluster harness connector terminal B13 (Black/White wire) and ground. If resistance is less than 5 ohms, replace instrument cluster. See INSTRUMENT CLUSTER  under REMOVAL & INSTALLATION. If resistance is more than 5 ohms, repair open in Black/White wire.
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