Here is an updated bin with the tank size set to 42 gal. I made the first file before you said you needed that. But again it is a 04 Van segment so I don't know if it will help with your issue.

I saw your rely after I posted. You cannot swap a 02 segment into a 04 OS. OS have to match between the 2 files you are swapping between. That is why I used a 04 Van segment. If it has to be from a...

Here are a couple bins. One is your file with just the return fuel injector data, and the other is same with 04 Van fuel system segment which has the tank and gauge data in it swapped. Also it looks...

Are you wanting a 04 Van fuel system segment (segment 6) swapped into your file? If so I can do that. And I can also input the return style injector data. That is easy.

This is the best I can do showing you the differences between a 99 and 04 OS Fuel Gauge calibrations. I used excel files for a couple of the tables because the tables were too big for screen shots....

The fuel gauge tables in a 99 Black Box PCM that are going to control a 99 cluster are nowhere near compatible or transferable from a 04 P59 OS. Tunerpro doesn't even show all the 04 tables either. ...

Just to verify your 99 Suburban was originally a Black Box 4 connector PCM? And it looks like for some reason it is a 04 OS that you put a 03 Sierra VIN in it? What fuel system? Return or returnless?...

Post the bin you are using and I'll see what I can do.