Diagnostic Test

CHECK FOR FUEL LEVEL SENSOR CIRCUIT DTCS
NOTE:
Diagnose and repair any CAN BUS, communication or implausible signal DTCs before proceeding with this test.

NOTE:
Excessive pressure build up or vacuum in the Evaporative system could possibly contribute to this DTC being set. Diagnose and repair any Evaporative System DTCs before continuing with this fault.
1. Turn the ignition on.
2. With the scan tool, read and record DTCs on the repair order.
  Are any Fuel Level Sensor Circuit DTCs present?
  
  Yes
  - Diagnose the appropriate Fuel Level Sensor Circuit DTCs before continuing.
  - Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
  No
  - Go To 2
VISUALLY INSPECT FUEL TANK
1. Turn the ignition off.
2. Visually inspect the Fuel Tank for any obvious physical damage that may restrict the Fuel Sending Unit float from moving.
  Is the Fuel Tank damaged?
  
  Yes
  - Replace the Fuel Tank in accordance with the Service Information.
  - Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
  No
  - Go To 3
INTERNAL INSPECTION OF THE FUEL TANK
WARNING:
The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury.
1. Remove the Fuel Tank in accordance with the Service Information. Refer to TANK, FUEL, REMOVAL .
2. Remove the Fuel Pump Module. Refer to MODULE, FUEL PUMP, REMOVAL .
3. Visually inspect the inside of the Fuel Tank for any obstructions or deformities.
4. Inspect the Fuel Level Sensor for any signs of damage.
  Were any issues found with the Fuel Level Sensor?
  
  Yes
  - Replace the Fuel Level Sensor in accordance with the Service Information.
  - Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
  No
  - Go To 4
CHECK RELATED PCM AND COMPONENT CONNECTIONS
1. Perform any Service Bulletins that apply.
2. Disconnect all PCM harness connectors.
3. Disconnect all related in-line harness connections (if equipped).
4. Disconnect the related component harness connectors.
5. Inspect harness connectors, component connectors, and all male and female terminals for the following conditions:
  - Proper connector installation.
  - Damaged connector locks.
  - Corrosion.
  - Other signs of water intrusion.
  - Weather seal damage (if equipped).
  - Bent terminals.
  - Overheating due to a poor connection (terminal may be discolored due to excessive current draw).
  - Terminals that have been pushed back into the connector cavity.
  - Check for spread terminals and verify proper terminal tension.
  Repair any conditions that are found.
6. Reconnect all PCM harness connectors. Be certain that all harness connectors are fully seated and the connector locks are fully engaged.
7. Reconnect all in-line harness connectors (if equipped). Be certain that all connectors are fully seated and the connector locks are fully engaged.
8. Reconnect all related component harness connectors. Be certain that all connectors are fully seated and the connector locks are fully engaged.
9. With the scan tool, erase DTCs.
10. Test drive or operate the vehicle in accordance with the when monitored and set conditions.
11. With the scan tool, read DTCs.
  Did the DTC return?
  
  Yes
  - Replace the Powertrain Control Module in accordance with the Service information. Refer to MODULE, POWERTRAIN CONTROL, REMOVAL .
  - Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
  No
  - Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
  - Test complete.