GM Service Manual Online
For 1990-2009 cars only

Object Number: 891374  Size: MF

Circuit Description

The fuel level sender changes resistance based on the fuel level. The engine control module (ECM)/powertrain control module (PCM) monitors the signal circuit of the fuel level sender in order to determine fuel level. When the fuel tank is full, the sender resistance is high and the ECM/PCM senses a high signal voltage. When the fuel tank is empty, the sender resistance is low and the ECM/PCM senses a low signal voltage. The ECM/PCM uses the signal circuit of the fuel level sender in order to calculate the total remaining fuel percent in the tank. The ECM/PCM sends the fuel level percent via the class 2 serial data circuit to the body control module (BCM). The BCM sends that class 2 message to the instrument panel cluster (IPC) in order to display the fuel level percent on the fuel gage. The fuel level information is also used for misfire and evaporative emission (EVAP) diagnostics.

This diagnostic tests for a lower than normal fuel level sender signal.

Conditions for Running the DTC

The ignition is ON, with the engine ON.

Conditions for Setting the DTC

    • The fuel level signal is less than 3.5 percent.
    • The above condition is present for greater than 5 seconds.

Action Taken When the DTC Sets

    • The fuel gage defaults to empty.
    • The ECM/PCM records the operating conditions at the time the diagnostic fails. The ECM/PCM displays the failure information in the Failure Records on the scan tool.

Conditions for Clearing the DTC

    • The DTC becomes history when the conditions for setting the DTC are no longer present.
    • The history DTC clears after 40 malfunction free warm-up cycles.
    • The ECM/PCM receives the clear code command from the scan tool.

Diagnostic Aids

Use the Freeze Frame and/or Failure Records data in order to locate an intermittent condition. If you cannot duplicate the DTC, the information included in the Freeze Frame and/or Failure Records data may aid in determining the number of miles since the DTC set. The Fail Counter and Pass Counter can also aid in determining the number of ignition cycles that the diagnostic reported a pass and/or fail. Operate the vehicle within the same freeze frame conditions, i.e. RPM, engine load, vehicle speed, temperature, etc. This will isolate when the DTC failed.

Refer to Testing for Intermittent Conditions and Poor Connections in Wiring Systems.

Test Description

The number below refers to the step number on the diagnostic table.

  1. Tests for the proper operation of the circuit in the high voltage range.

Step

Action

Values

Yes

No

Schematic Reference: Instrument Cluster Schematics

1

Did you perform the Diagnostic System Check - Instrument Cluster?

--

Go to Step 2

Go to Diagnostic System Check - Instrument Cluster

2

  1. Install a scan tool.
  2. Turn the ignition ON, with the engine OFF.
  3. With a scan tool, observe the Fuel Level parameter in the engine control module (ECM)/powertrain control module (PCM) engine data list.

Does the scan tool indicate that the Fuel Level parameter is less than the specified value?

3.5%

Go to Step 3

Go to Diagnostic Aids

3

  1. Turn the ignition OFF.
  2. Disconnect C406.
  3. Turn the ignition ON, with the engine OFF.
  4. With a scan tool, observe the Fuel Level parameter.

Does the scan tool indicate that the Fuel Level parameter is greater than the specified value?

98%

Go to Step 5

Go to Step 4

4

Test the signal circuit of the fuel level sender for a short to ground. Refer to Circuit Testing and to Wiring Repairs in Wiring Systems.

Did you find and correct the condition?

--

Go to Step 10

Go to Step 7

5

Test the signal circuit of the fuel level sender for a short to ground between C406 and the fuel level sender. Refer to Circuit Testing and to Wiring Repairs in Wiring Systems.

Did you find and correct the condition?

--

Go to Step 10

Go to Step 6

6

Inspect for poor connections at the harness connector of the fuel level sender. Refer to Testing for Intermittent Conditions and Poor Connections and to Connector Repairs in Wiring Systems.

Did you find and correct the condition?

--

Go to Step 10

Go to Step 8

7

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

Did you find and correct the condition?

--

Go to Step 10

Go to Step 9

8

Replace the fuel level sender. Refer to Fuel Level Sensor Replacement in Engine Controls - 2.2L (L61) or to Fuel Level Sensor Replacement in Engine Controls - 2.2L (LSJ).

Did you complete the replacement?

--

Go to Step 10

--

9

Important: Program the replacement ECM/PCM.

Replace the ECM/PCM. Refer to Engine Control Module Replacement in Engine Controls - 2.2L (L61) or to Powertrain Control Module Replacement in Engine Controls - 2.0L (LSJ).

Did you complete the replacement?

--

Go to Step 10

--

10

  1. Use the scan tool in order to clear the DTCs.
  2. Operate the vehicle within the Conditions for Running the DTC as specified in the supporting text.

Does the DTC reset?

--

Go to Step 2

System OK