GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2002 🢒 Chevy C Cab/Chassis HD (GMT 400) 🢒 Engine 🢒 Engine Electrical 🢒 Poor Fuel Economy

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DEFINITION: Fuel economy, as measured by an actual road test, is noticeably lower than expected. Also, fuel economy is noticeably lower than previously noted on this vehicle, as previously shown by an actual road test.

Preliminary
    • Refer to Important Preliminary Checks Before Starting in Symptoms - Engine Controls .
    • Search for bulletins.
    • Inspect the powertrain control module (PCM) grounds for being clean, tight, and in the proper locations. Refer to Engine Controls Schematics .
    • Check the owners driving habits.
       - Is the A/C ON or the Defroster mode ON full time?
       - Are the tires at the correct pressure?
       - Is there excessively heavy loads being carried?
       - Is the acceleration rate too much, too often?
       - Remove the air filter elemen. Inspect for dirt or for being restricted. Refer to Air Cleaner Element Replacement . Replace as necessary.

Fuel System
    • Reviewthe type, quality, and alcohol content of the fuel. Oxygenated fuels have lower energy and may deliver reduced fuel economy. Refer to Fuel System Specifications and Alcohol/Contaminants-in-Fuel Diagnosis .
    • Inspect the fuel injectors. Refer to Fuel Injector Solenoid Coil Test .
    • Inspect for incorrect fuel pressure. Refer to Fuel System Diagnosis .
    • Inspect for a restricted fuel filter. Refer to Fuel System Diagnosis .
    • Inspect for a contaminated fuel condition. Refer to Alcohol/Contaminants-in-Fuel Diagnosis .
    • Verify that each injector harness is connected to the correct injector and cylinder according to the firing order: 1-8-7-2-6-5-4-3. Relocate the injector harnesses as necessary.
    • Inspect for foreign material accumulation in the throttle bore, coking on the throttle valve, or on the throttle shaft.
    • Inspectitems that cause an engine to run rich long term fuel trim near -13 percent. For a rich condition, refer to DTC P0132 or P0152 .

Sensor/System
    • Inspect the air intake system and crankcase for air leaks.
    • Inspect the crankcase ventilation valve for proper operation. Place a finger over the inlet hole in the valve end several times. The valve should snap back. If not, replace the valve.
    • Inspect for proper calibration of the speedometer. Connect J 33431-B Signal Generator to the vehicle speed sensor (VSS) electrical connector. Turn ON the ignition with the tester ON and monitor the speedometer. The speedometer should indicate 86 km/h (54 mph).
    • Use a scan tool in order to monitor the knock sensor (KS) system for excessive spark retard activity. Refer to Knock Sensor (KS) System Description .

Ignition System
    • Inspect for proper ignition voltage output with J 26792 Spark Tester .
    • Remove the spark plugs. Inspect for the following conditions. Refer to Spark Plug Inspection .
       - Wet plugs
       - Cracks
       - Wear
       - Improper gap
       - Burned electrodes
       - Heavy deposits
    • An improper spark plug gap will cause a driveability problem. Gap the spark plugs using a wire gage gap tool. Refer to Spark Plug Replacement .
    • Determine the cause of the fouling before replacing the spark plugs if the spark plugs are gas, coolant, or oil fouled. Refer to Spark Plug Inspection for diagnosis of fouled spark plugs.
    • Inspect the secondary ignition for the following conditions:
       - Ignition wires arcing to ground
       - Ignition wires for proper routing
    • Wetting down the secondary ignition system with water from a spray bottle may help locate damaged or deteriorated components. Look and listen for arcing or misfiring as you apply water.
    • Inspect for loose ignition coil grounds. Refer to Electronic Ignition (EI) System Diagnosis .

Engine Cooling System
    • Inspect the engine coolant level for being low. Refer to Loss of Coolant in Engine Cooling.
    • Inspect the engine thermostat for proper operation and for the correct heat range. Refer to Thermostat Diagnosis in Engine Cooling.

Engine Mechanical
    • Check engine mechanical for the following conditions:
       - Sticking or leaking valves
       - Worn camshaft lobes
       - Valve timing
       - Bent push rods
       - Worn rocker arms
       - Broken valve springs
       - Excessive oil in combustion chamber--Leaking valve seals. Refer to Oil Consumption Diagnosis in Engine Mechanical 8.1L .
       - Low cylinder compression--Refer to Engine Compression Test in Engine Mechanical 8.1L.
    • Inspect the following components for incorrect basic engine parts:
       - The cylinder heads
       - The camshaft
       - The pistons, etc.

Refer to the appropriate procedures in Engine Mechanical 8.1L for diagnosis procedures.

Additional Checks
    • Inspect the vacuum hoses for splits, kinks, and proper connections and routing as shown on Vehicle Emission Control Information label.
    • Inspect the following components of the exhaust system for possible restrictions:
       - The exhaust system for damaged or collapsed pipes
       - The exhaust manifold for a collapsed inner wall
       - The mufflers for heat distress or possible internal failure
       - The three-way catalytic converters for possible plugged conditions--Compare the exhaust system back pressure on each side of engine. Refer to Restricted Exhaust in Engine Exhaust.
    • Electromagnetic interference (EMI) on the reference circuit can cause an engine miss condition. A scan tool can usually detect EMI by monitoring the engine RPM. A sudden increase in RPM with little change in actual engine RPM change indicates EMI is present. Inspect for high voltage components, near ignition control circuits, if a problem exists.
    • Inspect the park neutral position (PNP) switch circuit.
    • Inspect the intake and the exhaust manifold passages for casting flash.
    • Inspect the brake system for dragging or improper operation. Refer to Brake Caliper Inspection in Brakes. Ensure that the vehicle operator does not drive with a foot on the brake pedal.