GM Service Manual Online
For 1990-2009 cars only

Fuel Gauge Always Indicates Full Gas

Step

Action

Value(s)

Yes

No

Important:: Before performing the diagnostics below, perform a diagnostic circuit check and repair DTC's P0461, P0462, or P0463 pertaining to the fuel tank senders.

1

Did you perform the Instrument Cluster System Check?

--

Go to Step 2

Go to Instrument Cluster System Check

2

  1. Remove the IP Cluster.
  2. Disconnect the Vehicle Control Module (VCM) connector C1.
  3. Connect a DMM (ohms) between cavity 9 of VCM connector C1 and cavity 29 of the IP Cluster.

Is the resistance greater than the value given?

0.5ohms

Go to Step 3

Go to Step 4

3

Locate and repair the open or cause of resistance in CKT 30 (PPL) between VCM connector C1 and the IP Cluster. Refer to Wiring Repairs in Wiring Systems.

Is the repair complete?

--

Go to Instrument Cluster System Check

--

4

Replace the I/P Cluster. Refer to Instrument Cluster Replacement .

Is the repair complete?

--

Go to Instrument Cluster System Check

--

Fuel Gauge Always Indicates Full Diesel

Step

Action

Value(s)

Yes

No

1

Did you perform the Instrument Cluster System Check?

--

Go to Step 2

Go to Instrument Cluster System Check

2

  1. Disconnect the Fuel Pump and Sender connect at the left side frame rail.
  2. Connect a jumper wire on CKT 30 (PPL) between pin B of the Fuel Pump and Sender connector and ground.
  3. Turn the ignition switch to the RUN position.

Does the fuel gauge read empty?

--

Go to Step 6

Go to Step 3

3

Connect a J 39200 DMM (ohms) between cavities A & B of the Fuel Pump and Sender.

Does the resistance read according to the fuel level?

0 ohms Empty/90 ohms Full

Go to Step 4

Go to Step 6

4

  1. Connect the Fuel Pump and Sender connector.
  2. Remove the I/P Cluster. Refer to Instrument Cluster Replacement
  3. Connect a J 39200 DMM between pin 29 of the I/P Cluster connector and ground.

Does the resistance read according to fuel level?

0 ohms Empty/90 ohms Full

Go to Step 5

Go to Step 7

5

Replace the I/P Cluster. Refer to Instrument Cluster Replacement

Is the repair complete?

--

Go to Instrument Cluster System Check

--

6

Replace the Fuel Pump and Sender. Refer to Fuel Sender Assembly Replacement in Engine Controls, 1999 C/K Service Manual.

Is the repair complete?

--

Go to Instrument Cluster System Check

--

7

Locate and repair the open in CKT 30 (PPL) between the I/P Cluster and Fuel Pump and Sender. Refer to Wiring Repairs in Wiring Systems.

Is the repair complete?

--

Go to Instrument Cluster System Check

--