• Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure.
• Review Strategy Based Diagnosis for an overview of the diagnostic approach.
• Diagnostic Procedure Instructions provides an overview of each diagnostic category.

The fuel level sensor changes resistance based on fuel level and is wired to the Fuel Pump Driver Control Module. The Fuel Pump Driver Control Module sends the fuel level sensor reading to the Engine Control Module (ECM) via serial data. The ECM monitors the fuel level sensor signal in order to determine the fuel level. When the fuel tank is full, the resistances of both fuel level sensors are low. When the fuel tank is empty, the resistances of the fuel level sensors are high. The ECM uses the signal voltages of the primary fuel level sensor and the secondary fuel level sensor (integrated in the fuel tank) to calculate the percentage of remaining fuel in the tank. The ECM sends the fuel level percentage via serial data to the body control module (BCM). The BCM then sends the fuel level percentage via serial data to the P16 Instrument Panel Cluster Control Module to control the fuel gauge.

• The engine is running
• The system voltage is between 11–16 V

The ECM detects a change in fuel level of less than a specified amount (typically 3–10 L or 0.8–2.6 gal) over a specified driving distance (typically 240–320 km or 150–200 miles).

• The signal voltage is less than 0.25 V.
• The above conditions must be met for 5 seconds.

• The signal voltage is greater than 4.7 V.
• The above conditions must be met for 5 seconds.

• The fuel level change is greater than 10%.
• The above conditions must be met for 30 seconds.
• DTC P0464 runs and fails 2 out of 3 test cycles.

• P0461, P0462, P0463, P0464, P2066, P2067 and P2068 are Type B DTCs
• The fuel gauge defaults to empty
• The low fuel indicator illuminates

• P0461, P0462, P0463, P0464, P2066, P2067 and P2068 are Type B DTCs
• 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.

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.
2. Verify the DTC P0461, P0462, P0463, P0464, P2066, P2067, or P2068 are not set
• If DTC P0461, P0462, P0463, or P0464 are set

  Refer to Primary Fuel Level Sensor Malfunction in Circuit/System Testing

• If DTC P2066, P2067, or P2068 are set

  Refer to Secondary Fuel Level Sensor Malfunction in Circuit/System Testing

• If DTC P0461, P0462, P0463, P0464, P2066, P2067, or P2068 are not set
3. If equipped, verify the fuel level gauge sweeps when performing the scan tool P16 Instrument Panel Cluster Control Module Gauge Sweep control function.
• If the fuel level gauge does not sweep

  Replace the P16 Instrument Panel Cluster Control Module.

• If the fuel level gauge sweeps
4. Ignition ON, Verify the low fuel level indicator turns ON and OFF during Instrument Panel Cluster initialization bulb check.
• If the low fuel level indicator does not turn ON and OFF

  Replace the P16 Instrument Panel Cluster Control Module

• If the low fuel level indicator turns ON and OFF
5. Verify the scan tool Fuel Level Sensor Left Tank parameter is between 0.5–3.5 V and varies with fuel level.
• If not between 0.5–3.5 V or does not vary with fuel level

  Refer to Primary Fuel Level Sensor Malfunction in Circuit/System Testing

• If between 0.5–3.5 V and varies with fuel level
6. Verify the scan tool Fuel Level Sensor Right Tank parameter is between 0.5–3.5 V and varies with fuel level.
• If not between 0.5–3.5 V or does not vary with fuel level

  Refer to Secondary Fuel Level Sensor Malfunction in Circuit/System Testing

• If between 0.5–3.5 V and varies with fuel level
7. All OK.

1. 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.
2. Test for less than 10 Ω between the low reference circuit terminal 6 and ground.
• If 10 Ω or greater
1. Ignition OFF, disconnect the harness connector at the K111 Fuel Pump Driver Control Module.
2. 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 Driver Control Module.
• If less than 10 Ω
3. Ignition ON.
4. Verify the scan tool Fuel Level Sensor Left Tank parameter is greater than 4.8 V.
• If 4.8 V or less
1. Ignition OFF, disconnect the harness connector at the K111 Fuel Pump Driver Control Module.
2. Test for infinite resistance between the signal circuit terminal 5 and ground.
• If less than infinite resistance, repair the short to ground on the circuit.
• If infinite resistance, replace the K111 Fuel Pump Driver Control Module.
• If greater than 4.8 V
5. Install a 3 A fused jumper wire between the signal circuit terminal 5 and the low reference circuit terminal 6.
6. Verify the scan tool Fuel Level Sensor Left Tank parameter is less than 0.2 V.
• If 0.2 V or greater
1. Ignition OFF, disconnect the harness connector at the K111 Fuel Pump Driver Control Module, ignition ON.
2. 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.
• If less than 1 V
3. Ignition OFF
4. 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 Driver Control Module.
• If less than 0.2 V
7. Test or replace the B46A Primary Fuel Level Sensor.
8. Operate the vehicle within the Conditions for Running the DTC.
9. Verify the condition does not return.
• If the condition returns

  Replace the K20 Engine Control Module.

• If the condition does not return
10. All OK.

1. 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.
2. Test for less than 10 Ω between the low reference circuit terminal 8 and ground.
• If 10 Ω or greater
1. Ignition OFF, disconnect the harness connector at the K111 Fuel Pump Driver Control Module.
2. 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 Driver Control Module.
• If less than 10 Ω
3. Ignition ON.
4. Verify the scan tool Fuel Level Sensor Right Tank parameter is greater than 4.8 V.
• If 4.8 V or less
1. Ignition OFF, disconnect the harness connector at the K111 Fuel Pump Driver Control Module.
2. Test for infinite resistance between the signal circuit terminal 7 and ground.
• If less than infinite resistance, repair the short to ground on the circuit.
• If infinite resistance, replace the K111 Fuel Pump Driver Control Module.
• If greater than 4.8 V
5. Install a 3 A fused jumper wire between the signal circuit terminal 7 and the low reference circuit terminal 8.
6. Verify the scan tool Fuel Level Sensor Right Tank parameter is less than 0.2 V.
• If 0.2 V or greater
1. Ignition OFF, disconnect the harness connector at the K111 Fuel Pump Driver Control Module, ignition ON.
2. 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.
• If less than 1 V
3. Ignition OFF
4. 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 Driver Control Module.
• If less than 0.2 V
7. Test or replace the B46B Fuel Level Sensor – Secondary.
8. Operate the vehicle within the Conditions for Running the DTC.
9. Verify the condition does not return.
• If the condition returns

  Replace the K20 Engine Control Module.

• If the condition does not return
10. All OK.

1. Ignition OFF, remove the Primary Fuel Level Sender.
2. Sweep the Fuel Level Sensor through its full range of motion while measuring resistance between the signal terminal 5 and the low reference terminal 6.
3. Test for a minimum resistance value of 37-43 Ω and a maximum value of 245-255 Ω without any spikes or dropouts.
• If minimum resistance is not 37-43 Ω, maximum resistance is not 245-255 Ω, or if there are any spikes or dropouts

  Replace the Primary Fuel Level Sensor.

• If minimum resistance is 37-43 Ω, maximum resistance is 245-255 Ω, and if there are no spikes or dropouts
4. All OK.

Perform the Diagnostic Repair Verification after completing the repair.

• Displays and Gauges Component Replacement Reference
• Control Module References for control module replacement, programming, and setup