Fuel Gage Inaccurate or Inoperative 2.0L and 2.2L
Diagnostic Aids
| • | Ensure that the fuel level is in the same range as the customer concern. |
| • | For intermittent diagnosis, refer to Testing for Intermittent Conditions and Poor Connections . |
| • | Refer to Fuel Level Specifications in order to verify the correct fuel level sensor readings. The Fuel Level Sensor parameter is available on the scan tool in the engine control module (ECM)/powertrain control module (PCM) Data list. |
Test Description
The numbers below refer to the step number on the diagnostic table.
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This step tests for a high resistance in the signal circuit and the low reference circuit of the fuel level sensor.
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DTCs will be set in the ECM/PCM when you perform this diagnostic table.
Step | Action | Values | Yes | No | ||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|
Schematic Reference: Instrument Cluster Schematics | ||||||||||||
1 | Did you perform the Diagnostic System Check - Vehicle? | -- | Go to Step 2 | |||||||||
2 |
Important: Verify the SA9205Z resistance settings with a DMM. Does the fuel gage display the correct fuel level? | -- | Go to Step 4 | Go to Step 3 | ||||||||
Important: Verify the SA9205Z resistance settings with a DMM. Important: Turn the ignition OFF momentarily between the resistance settings in order to quickly update the scan tool display. Does the Fuel Level parameter display the correct fuel level percentage? | -- | Go to Step 11 | Go to Step 5 | |||||||||
4 | Inspect for the following items:
Did you find and correct the condition? | -- | Go to Step 13 | Go to Step 7 | ||||||||
5 | Test the signal circuit of the fuel level sensor for a high resistance. Refer to Circuit Testing and Wiring Repairs . Did you find and correct the condition? | -- | Go to Step 13 | Go to Step 6 | ||||||||
6 | Test the low reference circuit of the fuel level sensor for a high resistance. Refer to Circuit Testing and Wiring Repairs . Did you find and correct the condition? | -- | Go to Step 13 | Go to Step 9 | ||||||||
7 |
Did you find and correct the condition? | -- | Go to Step 13 | Go to Step 8 | ||||||||
8 |
Does the resistance change smoothly across the specified range? | 40-250 ohms | Go to Diagnostic Aids | Go to Step 10 | ||||||||
9 | Inspect for poor connections at the harness connector of the ECM/PCM. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs . Did you find and correct the condition? | -- | Go to Step 13 | Go to Step 12 | ||||||||
10 | Replace the fuel level sensor. Refer to Fuel Level Sensor Replacement for the 2.2L (L61) engine or Fuel Level Sensor Replacement for the 2.0L engine. Did you complete the replacement? | -- | Go to Step 13 | -- | ||||||||
11 | Replace the instrument panel cluster (IPC). Refer to Control Module References for replacement, setup, and programming. Did you complete the replacement? | -- | Go to Step 13 | -- | ||||||||
12 | Replace the ECM/PCM. Refer to Control Module References for replacement, setup, and programming. Did you complete the replacement? | -- | Go to Step 13 | -- | ||||||||
Did you correct the condition? | -- | System OK | Go to Step 2 | |||||||||
Fuel Gage Inaccurate or Inoperative 2.4L
Diagnostic Fault Information
Important: Always perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure.
Circuit/System Description
The fuel level sensor changes resistance in response to the fuel level. The engine control module (ECM) monitors the signal circuit of the fuel level sensor in order to determine the fuel level. When the fuel tank is full, the sensor resistance is low and the ECM senses a low signal voltage. When the fuel tank is empty, the sensor resistance is high and the ECM senses a high signal voltage. The ECM uses the signal circuit of the fuel level sensor in order to calculate the percentage of remaining fuel in the tank. The ECM sends the fuel level percentage via the GMLAN serial data circuit to the body control module (BCM). The BCM sends the fuel information to the instrument panel cluster via the GMLAN serial data circuit in order to control the fuel gage and display the fuel level. Then fuel information is also used for misfire and evaporative emission (EVAP) diagnostics.
Reference Information
Schematic Reference
| • | Engine Controls Schematics for the 2.4L engine. |
Connector End View Reference
| • | Engine Control Module Connector End Views for the 2.4L engine |
Electrical Information Reference
Scan Tool Reference
Circuit/System Testing
- Ignition OFF, disconnect the fuel level sensor connector, install a signal generator and instrument panel tester between the signal circuit and the low reference circuit.
- Ignition ON, vary the resistance on the signal generator from 40 ohms - 250 ohms. With the scan tool verify that the Fuel Tank Level Remaining parameter displays the correct fuel level percent. Refer to Fuel Level Specifications .
- Ignition ON, vary the resistance on the signal generator from 40 ohms - 250 ohms. Observe the fuel gage and verify that the fuel gage displays the correct fuel level. Refer to Fuel Level Specifications .
- If all circuits test normal, test or replace the fuel level sensor.
| ⇒ | If the fuel level percent is incorrect, test the signal circuit and the low reference circuit for an open/high resistance. If all circuit tests normal, replace the ECM. |
| ⇒ | If the fuel gage display is incorrect, test or replace the fuel gage. |
Component Testing
Measure the resistance of the float arm of the fuel level sender while moving the float arm between 40-250 ohms.
Repair Instructions
Important: Always perform the Diagnostic Repair Verification after completing the diagnostic procedure.
| • | Fuel Level Sensor Replacement for the 2.4L engine. |
| • | Control Module References for the ECM and IPC replacement, setup, and programming |
