• Perform the Diagnostic System Check prior to using this diagnostic procedure:Diagnostic System Check - Vehicle
• Review the description of Strategy Based Diagnosis:Strategy Based Diagnosis
• An overview of each diagnostic category can be found here:Diagnostic Procedure Instructions

For an overview of the component/system, refer to:Instrument Cluster Description and Operation

Ignition » On / Vehicle » In Service Mode

Fuel Level Sensor SignalChange=Less than 3-10 L/0.8-2.6Gallons US—Distance Traveled=Greater than 240-320 km (150-200 mi)

Fuel Level Sensor Signal=Less than 0.25 V

The above condition(s) must occur for greater than 5 s.

Fuel Level Sensor Signal=Greater than 4.7 V

The above condition(s) must occur for greater than 30 s.

Fuel Level Sensor Signal=Change is greater than 10%.

The above condition(s) must occur for greater than 30 s.

The diagnostic fails 2 out of 3 test cycles.

• DTCs listed in the DTC Descriptor category=Type B DTC
• Fuel Gauge=Empty
• Low Fuel Indicator=On

• DTCs listed in the DTC Descriptor category=Type B DTC
• The conditions for setting the DTC no longer exist.
• A history DTC will clear after 40 consecutive malfunction-free ignition cycles.

Instrument Cluster Schematics

Master Electrical Component List

Instrument Cluster Description and Operation

• Circuit Testing
• Connector Repairs
• Testing for Intermittent Conditions and Poor Connections
• Wiring Repairs

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Control Module References for scan tool information

1. Ignition » On / Vehicle » In Service Mode
2. Verify the DTC P0461, P0462, P0463, or P0464 are not set
• If DTC P0461, P0462, P0463, or P0464 are set

  Refer to Circuit/System Testing

• If DTC P0461, P0462, P0463, or P0464 are not set
3. If equipped, Perform the scan tool control function:Fuel Gauge Sweep

   Verify the component activates:Fuel Gauge

• If the component does not activate

  Test or replace the component:P16 Instrument Cluster

• If the component activates
4. Verify the scan tool parameter:Fuel Level Sensor=0.5 to 3.5 V and changes&Varies with changes in fuel level.
• If not between 0.5 and 3.5 V or does not change

  Refer to Circuit/System Testing.

• If between 0.5 and 3.5 V and changes
5. All OK.

Note: It may take up to 2 min for all vehicle systems to power down before an accurate ground or low reference circuit continuity test can be performed.

1. Ignition/Vehicle & All vehicle systems » Off
2. Disconnect the electrical connector:A7 Fuel Pump and Level Sensor Assembly
3. Test for less than 10 Ω between the test points:Low Reference circuit terminal 6&Ground
• If 10 Ω or greater
1. Disconnect the electrical connector:K20 Engine Control Module
2. Test for less than 2 Ω between the test points:Low Reference circuit terminal@Component harness&The other end of the circuit
• If 2 Ω or greater » Repair the open/high resistance in the circuit.
• If less than 2 Ω » Replace the component:K20 Engine Control Module
• If less than 10 Ω
4. Ignition » On / Vehicle » In Service Mode
5. Verify the scan tool parameter:Remaining Fuel in Tank=Less than 5%
• If 5% or greater
1. Ignition/Vehicle » Off
2. Disconnect the electrical connector:K20 Engine Control Module
3. Test for infinite resistance between the test points:Signal circuit terminal 5@Component harness&Ground
• If less than infinite resistance » Repair the short to ground on the circuit.
• If infinite resistance » Replace the component:K20 Engine Control Module
• If less than 5%
6. Connect a 3 A fused jumper wire between the test points:Signal circuit terminal 5&Low Reference circuit terminal 6
7. Verify the scan tool parameter:Remaining Fuel in Tank=If 90% or greater
• If less than 90%
1. Ignition/Vehicle » Off & Remove » Jumper wire(s)
2. Disconnect the electrical connector:K20 Engine Control Module
3. Ignition » On / Vehicle » In Service Mode
4. Test for less than 1 V between the test points:Signal circuit@Component harness&Ground
• If 1 V or greater » Repair the short to voltage on the circuit.
• If less than 1 V
5. Ignition/Vehicle » Off
6. Test for less than 2 Ω between the test points:Signal circuit@Component harness&The other end of the circuit
• If 2 Ω or greater » Repair the open/high resistance in the circuit.
• If less than 2 Ω » Replace the component:K20 Engine Control Module
• If 90% or greater
8. Test or replace the component:B46 Fuel Level Sensor

1. Ignition/Vehicle & All vehicle systems » Off
2. Remove the fuel level sensor.
3. Test for 245 to 255 Ω between the test points:Signal circuit terminal 5&Low Reference circuit terminal 6—Fuel Level Sensor»Empty
• If not between 245 and 255 Ω

  Replace the component:Fuel Level Sensor

• If between 245 and 255 Ω
4. Test for 37 to 43 Ω between the test points:Signal circuit terminal 5&Low Reference circuit terminal 6—Fuel Level Sensor»Full
• If not between 37 and 43 Ω

  Replace the component:Fuel Level Sensor

• If between 37 and 43 Ω
5. Perform a component sweep test:Fuel Level Sensor
6. Test for 37-43 to 245-255 Ω between the test points:Signal circuit terminal 5&Low Reference circuit terminal 6
7. The value should not spike or drop out while moving the sensor through the entire range.
• If not between 37-43 and 245-255 Ω or spikes or drops out

  Replace the component:Fuel Level Sensor

• If between 37-43 and 245-255 Ω and there are no spikes or drops out
8. All OK.

Perform the Diagnostic Repair Verification after completing the repair:Diagnostic Repair Verification

• Displays and Gauges Component Replacement Reference
• For control module replacement, programming, and setup refer to:Control Module References