For 1990-2009 cars

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. Turn the ignition switch to RUN.
2. Use the Scan Tool instrument panel cluster (IPC) function in order to read the diagnostic trouble codes (DTCs).

Does the scan tool display DTC B0092 (fuel sender problem)?

--

Go to Step 4

Go to Step 3

3 |

1. Turn the ignition switch to OFF.
2. Disconnect the fuel tank unit connector.
3. Connect 2 red leads from the J 33431-C tester to terminal A (PPL) and terminal D (BLK/WHT) of C420.
4. Set the tester resistance dial to 40 ohms (Empty), then to 250 ohms (Full).
5. Cycle the ignition switch from OFF to RUN after each resistance value is dialed in.

Does the fuel gauge display E at 40 ohms and F at 250 ohms?

--

Go to Step 8

Go to Step 7

4 |

1. Turn the ignition switch OFF.
2. Disconnect the fuel tank unit connector.
3. Use a fused jumper in order to connect the fuel tank unit harness connector terminal A (PPL) to ground.
4. Turn the ignition switch to RUN.

Does the fuel gauge now read empty before 3 minutes?

--

Go to Step 6

Go to Step 5

5 |

1. Turn the ignition switch to OFF.
2. Disconnect the instrument cluster connector.
3. Test CKT 30 (PPL) for an open.
4. Test the instrument cluster connector C1 terminal E4 (Buick) or connector C1 terminal C2 (Oldsmobile) for proper terminal contact.
5. Are the circuits OK?

--

Go to Step 9

Go to Step 11

6 |

1. Turn the ignition switch to OFF.
2. Test CKT 651 (BLK/WHT) for an open.
3. Test the fuel tank unit connector for proper terminal contact at terminals A and D of C420.
4. Test the fuel level sender pigtail wiring in the fuel tank unit for damage.
5. If the circuits are OK, replace the fuel level sender.

Is the repair complete?

--

Go to Instrument Cluster System Check

--

7 |

1. Test CKT 30 (PPL) for a short to ground or an open.
2. Test CKT 651 (BLK/WHT) for an open.
3. Test the instrument cluster connector C1 terminals F16 and E4 (Buick) or connector C1 terminals C2 and C13 (Oldsmobile) for proper terminal contact.
4. If the circuits are OK, replace the instrument cluster.

Is the repair complete?

--

Go to Instrument Cluster System Check

--

8 | For Buick only, does the low fuel LED indicator illuminate when the fuel gauge displays E? | -- | Go to Step 10 | Go to Step 9
9 | Replace the instrument cluster. Is the replacement complete? | -- | Go to Instrument Cluster System Check | --
10 |

1. Test the fuel tank unit connector for proper terminal contact at terminals A and D of C420.
2. Test the fuel level sender pigtail wiring in the fuel tank unit for damage.
3. If the circuit is OK, replace the fuel level sender.

Is the repair complete?

--

Go to Instrument Cluster System Check

--

11 | Repair the affected circuit. Is the repair complete? | -- | Go to Instrument Cluster System Check | --