stealthy_2005

The gas gauge in my 2004 GTO isn't working... Is this a common problem? Easy fix? Help!!! I just bought the car and I'm stumped...

Jontall

Fuel Gage Inaccurate or Inoperative
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 in Wiring Systems.

Test Description
The numbers below refer to the step numbers on the diagnostic table.

Access the fuel level sender through the trunk.

This step tests for a high resistance in the signal circuit and the low reference circuit of the fuel level sensor.

DTCs are set in the powertrain control module (PCM) when you perform this diagnostic table.

Step
Action
Value(s)
Yes
No

Schematic Reference: Instrument Cluster Schematics

1
Did you perform the Diagnostic System Check - Vehicle?
--
Go to Step 2
Go to Diagnostic System Check - Vehicle

2
Disconnect the fuel level sender.
Connect the J 33431-C Signal Generator and Instrument Panel Tester between the signal circuit of the fuel level sensor and the low reference circuit of the fuel level sensor on the male terminal side.
Turn the ignition ON, with the engine OFF.
Important: Verify the J 33431-C resistance settings with a DMM.


Vary the resistance on the J 33431-C from 40-250 ohms.
Does the fuel gage display the correct fuel level?
--
Go to Step 4
Go to Step 3

3
Install a scan tool.
Turn ON the ignition, with the engine OFF.
Important: Verify the resistance settings with a DMM.


Vary the resistance on the signal generator from 40-250 ohms.
Important: Turn the ignition OFF momentarily between the resistance settings in order to quickly update the scan tool display.


With the scan tool, observe the Fuel Tank Level Remaining parameter in the PCM EVAP Data list.
Does the Fuel Tank Level Remaining parameter display the correct fuel level?
--
Go to Step 11
Go to Step 5

4
Inspect for the following items:

• A poor connection at the harness connector of the fuel level sensor--Refer to Testing for Intermittent Conditions and Poor Connections and to Connector Repairs in Wiring Systems.
• A misaligned fuel level sender
• A deformed fuel tank

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 in Wiring Systems.

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 in Wiring Systems.

Did you find and correct the condition?
--
Go to Step 13
Go to Step 9

7
Remove the fuel level sender.
Inspect for the following items: • A stuck fuel level sender, i.e. the fuel strainer interfering with the sender float arm
• Foreign material in the fuel tank, i.e. ice

Did you find and correct the condition?
--
Go to Step 13
Go to Step 8

8
With the DMM, measure the resistance of the fuel level sensor while moving the float arm.
Observe both the analog and digital displays on the DMM.
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 powertrain control module (PCM). Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs in Wiring Systems.

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 in Engine Controls.

Did you complete the replacement?
--
Go to Step 13
--

11
Replace the instrument panel cluster (IPC). Refer to Instrument Panel Cluster (IPC) Replacement .

Did you complete the replacement?
--
Go to Step 13
--

12
Replace the PCM. Refer to Engine Control Module (ECM) Replacement in Engine Controls.

Did you complete the replacement?
--
Go to Step 13
--

13
Use the scan tool in order to clear the PCM DTCs.
Operate the system in order to verify the repair.
Did you correct the condition?
--
System OK
Go to Step 2



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Document ID# 1557005
2005 Pontiac GTO

stealthy_2005

Good GOD!!! Lol! Thanks man

TipsyMcStagger

iTrader: (1)

Jontall, the above info is for an '04 with a the LS1. I have an LS2 with the E40 PCM from a 2006 GTO that I'm swapping into a 1998 BMW 328 (E36). I want to retain the EVAP system but I'l need to input fuel level info into the E40 to do so. I've seen other E36 BMW swaps do this successfully but they were LS1 swaps with the 411 PCM.

Do you have any idea if the E40 PCM receives the fuel level info in the same manner as the LS1 equipped GTO's do? I know that the fuel level gauge on the 2006 is driven by the BCM, so I'm wondering if there's a serial signal at play for the EVAP information. I don't see the BCM mentioned at all in the above 2004 fuel level trouble shooting guide.

I'm hoping I can just input the analog fuel signal level straight from the BMW's fuel level sender into the E40 PCM and get the info I need for a functioning EVAP.

Thanks.

Tipsy