GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2006 🢒 G6 🢒 Body 🢒 Instrument Panel, Gages, and Console 🢒 Fuel Gage Inaccurate or Inoperative

Diagnostic Aids
    • Ensure that the fuel level is in the same range as the customer concern.
    • For intermittent diagnosis, refer to Testing for Intermittent Conditions and Poor Connections .
    • Refer to Fuel Level Specifications in order to verify the correct fuel level sender readings. The fuel level is available on the scan tool in the Fuel Tank Level Remaining (%) parameter in the powertrain control module (PCM) or the engine control module (ECM) enhanced evaporative emission (EVAP) data list.

Test Description

The numbers below refer to the step numbers on the diagnostic table.

  1. This step tests for high resistance in the signal circuit and the low reference circuit of the fuel level sender.

    2.

  2. DTCs will be set in the PCM/ECM when you perform this diagnostic table.

Step

Action

Values

Yes

No

Schematic Reference: Instrument Cluster Schematics , Engine Controls Schematics for the 2.4L engine, Engine Controls Schematics for the 3.5L engine or Engine Controls Schematics for the 3.9L engine

Connector End View Reference: Instrument Panel, Gages, and Console Connector End Views , Engine Control Module Connector End Views for the 2.4L engine, Powertrain Control Module Connector End Views for the 3.5L engine or Powertrain Control Module Connector End Views for the 3.9L engine

1

Did you perform the Diagnostic System Check - Vehicle?

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Go to Step 2

Go to Diagnostic System Check - Vehicle

2
  1. Disconnect C413.
  2. Connect the J 33431-C Signal Generator and Instrument Panel Tester between the signal circuit of the fuel level sender and the low reference circuit of the fuel level sender (male terminal side).
  3. Turn ON the ignition, with the engine OFF.
  4. Vary the resistance on the J 33431-C from 40-250 ohms.

    5. Important: Verify the J 33431-C resistance settings with a DMM.

  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 the scan tool.
  2. Turn ON the ignition, with the engine OFF.
  3. Vary the resistance on the J 33431-C from 40-250 ohms.

    4. Important: Verify the J 33431-C resistance settings with a DMM.

  4. Refer to Fuel Level Specifications in order to convert from resistance to fuel level percent.

    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 powertrain control module (PCM) or the engine control module (ECM) enhanced evaporative emission (EVAP) Data list.

Does the scan tool display the correct fuel level percent?

--

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 sender--Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs .
    • A high resistance in the signal circuit or the low reference circuit between the fuel level sender and C413
    • 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 sender for a high resistance between C413 and the PCM/ECM. Refer to Circuit Testing and Wiring Repairs .

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 sender for a high resistance between C413 and the PCM/ECM. Refer to Circuit Testing and Wiring Repairs .

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:
    3. • A stuck fuel level sender, i.e. the fuel strainer interfering with the sender float arm
    • Foreign material in the fuel tank, i.e. ice

Did you find and correct the condition?

--

Go to Step 13

Go to Step 8

8
  1. With the DMM, measure the resistance of the fuel level sender 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 ohms

Go to Diagnostic Aids

Go to Step 10

9

Inspect for poor connections at the harness connector of the PCM/ECM. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs .

Did you find and correct the condition?

--

Go to Step 13

Go to Step 12

10

Replace the fuel level sender. Refer to:

    •  Fuel Level Sensor Replacement for the 2.4L engine
    •  Fuel Sender Assembly Replacement for the 3.5L engine
    •  Fuel Level Sensor Replacement for the 3.9L engine

Did you complete the replacement?

--

Go to Step 13

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11

Replace the instrument panel cluster (IPC). Refer to Control Module References for replacement, setup, and programming.

Did you complete the replacement?

--

Go to Step 13

--

12

Replace the PCM/ECM. Refer to Control Module References for replacement, setup, and programming.

Did you complete the replacement?

--

Go to Step 13

--

13

  1. Use the scan tool in order to clear the PCM/ECM DTCs.
  2. Operate the system in order to verify the repair.

Did you correct the condition?

--

System OK

Go to Step 2