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Home >> Hummer >> 2003 >> H2 >> Repair and Diagnosis >> Electrical >> Gauges >> Instrument Panel, Gages, And Console >> Diagnostic Information & Procedures >> Fuel Gage Inaccurate Or Inoperative >> Test Description

Test Description

The numbers below refer to the step numbers on the diagnostic table. See Fuel Gage Inaccurate or Inoperative .

  1. 3:  This step tests for a high resistance in the signal circuit and the low reference circuit of the fuel level sensor.
  2. 13:  DTCs will set in the 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 instrument panel cluster (IPC) Diagnostic System Check? - Go to Step 2  Go to Diagnostic System Check - Instrument Cluster 
2
  1. Disconnect C106.
  2. Connect the J 33431-C  Signal Generator and Instrument Panel Tester between the signal circuit of the fuel level sensor and the low reference circuit of the fuel level sensor on the male terminal side of the connector. See Special Tools .
  3. Turn ON the ignition, with the engine OFF.
    4. IMPORTANT: Verify the J 33431-C  resistance settings with a DMM. See Special Tools .
  4. Vary the resistance on the J 33431-C  from 40-250 Ω. See Special Tools .
  5. Refer to Fuel Level Specifications  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 ON the ignition, with the engine OFF.
    3. IMPORTANT: Verify the J 33431-C  resistance settings with a DMM. See Special Tools .
  3. Vary the resistance on the J 33431-C  from 40-250 Ω. See Special Tools .
  4. Refer to Fuel Level Specifications  in order to convert from resistance to fuel level percentage.
    5. IMPORTANT: Turn OFF the ignition 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 PCM Enhanced EVAP Data, data list.
Does the scan tool display the correct fuel level percentage?		 - Go to Step 11  Go to Step 5 
4 Inspect for the following items:
  • A poor connection at the harness connector of the fuel level sensor. Refer to Testing for Intermittent Conditions and Poor Connections and to Connector Repairs in Wiring Systems.
  • A high resistance in the signal circuit of the fuel level sensor or the low reference circuit of the fuel level sensor between the fuel level sensor and C106.
  • A misaligned fuel level sender.
  • A deformed fuel tank.

Did you find and correct the condition?		 - Go to Step 13  Go to Step 7 
5 Test the signal 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 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:
    • The fuel level sensor is stuck, perhaps due to an interference with the fuel strainer.
    • The fuel tank contains foreign material, for instance, 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 .
Did you complete the replacement?		 - Go to Step 13  -
11 Replace the IPC. Refer to Instrument Panel Cluster (IPC) Replacement .
Did you complete the replacement?		 - Go to Step 13  -
12
IMPORTANT: Program the replacement PCM.
Replace the PCM. Refer to POWERTRAIN CONTROL MODULE .Did you complete the replacement?		 - Go to Step 13  -
13 
  1. Use the 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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