System Software Upgrade-Fuel Level Sender On Board Diagnostic (Reprogram Powertrain Control Module (PCM))

This bulletin provides information about installing new Powertrain Control Module (PCM) software and calibration on certain 2004 Chevrolet Malibu model vehicles equipped with a 2.2L (RPO L61 -- VIN F) L4engine; Chevrolet Colorado or GMC Canyon model vehicles equipped with a 2.8L (RPO LK5 - VIN 8) L4 engine or 3.5L (RPO L52 - VIN 6) L5 engine; and all built for sale in California (RPO YF5). PCM reprogramming is necessary on these vehicles to update the "stuck" fuel level sensor On-Board Diagnostic detection capability. Install the new calibration on all affected vehicles identified on the VIN list included with this bulletin launch, including vehicles in new dealer inventory and any vehicles that return for service, for any reason, during the applicable vehicle warranty coverage period. To verify if an updated calibration is required, refer to the following procedure in this bulletin.

The GM Vehicle Inquiry System (GM VIS) must be checked to determine if a specific vehicle requires this action. If GMVIS indicates that this System Software Update remains "open" and PCM reprogramming has not take place otherwise after the TIS Broadcast or CD-ROM availability dates identified below, reprogram the PCM using a Tech 2 scan tool with the calibration update from Techline Information System (TIS) 2000. For the 2.8L (RPO LK5) L4 or 3.5L (RPO L52) L5 engine use data version 4.5 for 2004 or later, broadcast to dealers on April 17, 2004; and on TIS CD-ROM version 5.5 or later for 2004, mailed to dealers by May 5, 2004. For the 2.2L (RPO L61) L4 engine use data version 5.5 for 2004 or later, broadcast to dealers on May 22, 2004; and on TIS CD-ROM version 5 for 2004, mailed to dealers on June 9, 2004.

For vehicles repaired under the applicable 8 year 80,000 mile emission warranty, use: