Circuit / System Testing
NOTE:
Circuit / System Verification must be performed before proceeding with Circuit / System Testing.
Primary Fuel Level Sensor Malfunction
- Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the A7 Fuel Tank Fuel Pump Module. It may take up to 2 minutes for all vehicle systems to power down.
- Test for less than 10 Ω between the low reference circuit terminal 6 and ground.
- If 10 Ω or greater
- Ignition OFF, disconnect the harness connector at the K111 Fuel Pump Power Control Module.
- Test for less than 2 Ω in the low reference circuit end to end.
- If 2 Ω or greater, repair the open / high resistance in the circuit.
- If less than 2 Ω, replace the K111 Fuel Pump Power Control Module.
- Go to next step: If less than 10 Ω
- Ignition ON.
- Verify the scan tool Fuel Level Sensor parameter is greater than 95% (or 4.8 V).
- If less than 95% (or 4.8 V)
- Ignition OFF, disconnect the harness connector at the K111 Fuel Pump Power Control Module.
- Test for infinite resistance between the signal circuit terminal 5 @ A7 Fuel Tank Fuel Pump Module and ground.
- If less than infinite resistance, repair the short to ground on the circuit.
- If infinite resistance, replace the K111 Fuel Pump Power Control Module.
- Go to next step: If greater than 95% (or 4.8 V)
- Install a 3 A fused jumper wire between the signal circuit terminal 5 and the low reference circuit terminal 6.
- Verify the scan tool Fuel Level Sensor parameter is less than 5% (or 0.2 V).
- If greater than 5% (or 0.2 V)
- Ignition OFF, disconnect the harness connector at the K111 Fuel Pump Power Control Module, ignition ON.
- Test for less than 1 V between the signal circuit and ground.
- If 1 V or greater, repair the short to voltage on the circuit.
- Go to next step: If less than 1 V
- Ignition OFF
- Test for less than 2 Ω in the signal circuit end to end.
- If 2 Ω or greater, repair the open / high resistance in the circuit.
- If less than 2 Ω, replace the K111 Fuel Pump Power Control Module.
- Go to next step: If less than 5% (or 0.2 V)
- Test or replace the B46A Fuel Level Sensor- Primary.
- Operate the vehicle within the Conditions for Running the DTC.
- Verify the condition does not return.
- If the condition returns
Replace the K20 Engine Control Module / K45 Powertrain Control Module.
- Go to next step: If the condition does not return
- If the condition returns
- All OK.
Secondary Fuel Level Sensor Malfunction
- Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the A7 Fuel Tank Fuel Pump Module. It may take up to 2 minutes for all vehicle systems to power down.
- Test for less than 10 Ω between the low reference circuit terminal 2 and ground.
- If 10 Ω or greater
- Ignition OFF, disconnect the harness connector at the K111 Fuel Pump Power Control Module.
- Test for less than 2 Ω in the low reference circuit end to end.
- If 2 Ω or greater, repair the open / high resistance in the circuit.
- If less than 2 Ω, replace the K111 Fuel Pump Power Control Module.
- Go to next step: If less than 10 Ω
- Ignition ON.
- Verify the scan tool Fuel Level Sensor 2 parameter is greater than 95% (or 4.8 V).
- If less than 95% (or 4.8 V)
- Ignition OFF, disconnect the harness connector at the K111 Fuel Pump Power Control Module.
- Test for infinite resistance between the signal circuit terminal 1 @ A7 Fuel Tank Fuel Pump Module and ground.
- If less than infinite resistance, repair the short to ground on the circuit.
- If infinite resistance, replace the K111 Fuel Pump Power Control Module.
- Go to next step: If greater than 95% (or 4.8 V)
- Install a 3 A fused jumper wire between the signal circuit terminal 1 and the low reference circuit terminal 2.
- Verify the scan tool Fuel Level Sensor 2 parameter is less than 5% (or 0.2 V).
- If greater than 5% (or 0.2 V)
- Ignition OFF, disconnect the harness connector at the K111 Fuel Pump Power Control Module, ignition ON.
- Test for less than 1 V between the signal circuit and ground.
- If 1 V or greater, repair the short to voltage on the circuit.
- Go to next step: If less than 1 V
- Ignition OFF
- Test for less than 2 Ω in the signal circuit end to end.
- If 2 Ω or greater, repair the open / high resistance in the circuit.
- If less than 2 Ω, replace the K111 Fuel Pump Power Control Module.
- Go to next step: If less than 5% (or 0.2 V)
- Test or replace the B46B Fuel Level Sensor - Secondary.
- Operate the vehicle within the Conditions for Running the DTC.
- Verify the condition does not return.
- If the condition returns
Replace the K20 Engine Control Module / K45 Powertrain Control Module.
- Go to next step: If the condition does not return
- If the condition returns
- All OK.