GM Service Manual Online
For 1990-2009 cars only

Step

Action

Values

Yes

No

1

Did you review the Instrument Cluster Circuit Description and perform the necessary inspections?

--

Go to Step 2

Go to Instrument Cluster Circuit Description

2

Verify that the fuel gage is inoperative.

Does the fuel gage operate normally?

--

Go to Testing for Intermittent Conditions and Poor Connections in Wiring Systems.

Go to Step 3

3

  1. Turn the ignition switch to ON.
  2. Disconnect the fuel level sensor at C401
  3. Connect a red lead of the J 33431-C to the BLU/WHT wire on C401.
  4. Connect the other red to a known good ground.

Does the fuel gage indicate the appropriate reading at the specified resistance values?

Full-0ohms

3/4-15ohms

1/2-35ohms

1/4-60ohms

Empty-100ohms

Go to Step 4

Go to Step 6

4

Test for an open or high resistance in the BLK/YEL wire between the fuel level sensor and G103. Refer to Testing for Continuity in Wiring Systems.

Does an open or high resistance condition exist?

--

Go to Step 5

Go to Step 7

5

Repair the open or high resistance in the BLK/YEL wire between the fuel level sensor and G400. Refer to Wiring Repairs in Wiring Systems.

Did you complete the repair?

--

Go to Step 10

--

6

Replace the fuel gage. Refer to Fuel/Temperature Gage Replacement .

Did you complete the repair?

--

Go to Step 10

--

7

Test for an open or high resistance condition in the BLU/WHT wire between instrument panel cluster connector C3 and the fuel level sensor. Refer to Testing for Continuity in Wiring Systems.

Does an open or high resistance condition exist?

--

Go to Step 8

Go to Step 9

8

Repair the BLU/WHT wire between the instrument panel cluster assembly and the fuel level sensor. Refer to Wiring Repairs in Wiring Systems.

Did you complete the repair?

--

Go to Step 10

--

9

Replace the Fuel level sending unit. Refer to Fuel Sender Assembly Replacement in Engine Controls 1.6L, Fuel Sender Assembly Replacement in Engine Controls 2.0L.

Did you complete the replacement?

--

Go to Step 10

--

10

Operate the system in order to verify the repair.

Did you correct the condition?

--

System OK

Go to Step 3