LOW FUEL WARNING LIGHT FLASHES/MESSAGE RELATED TO LOW FUEL LEVEL INDICATED IN DISPLAY [SKYACTIV-G]

id0103s4886000

Troubleshooting item

Low fuel warning light flashes/message related to low fuel level indicated in display
Description
•  The low fuel warning light flashes.
•  A message related to a low fuel level is indicated in the display.
Possible cause
Note
•  Even though the fuel gauge indicates the presence of sufficient fuel, the fuel is not transferred from the fuel tank (sub) to the fuel tank (main), which may cause fuel shortage and then engine stalling. The body control module (BCM) triggers the low fuel warning light to flash to alert the customer of the risk of engine stalling.
•  Low fuel tank level
•  Low-pressure side fuel delivery system malfunction
―  Battery voltage decrease
―  Fuel pump unit malfunction
•  Fuel filter (high-pressure) clogged (built-into fuel pump unit)
•  Fuel filter (low-pressure) clogged (built-into fuel pump unit)
•  Pressure regulator (built-into fuel pump unit) malfunction
•  Jet pump (built-into fuel pump unit) malfunction
―  Fuel tank malfunction
•  Clogging in hose between fuel tank (main) and fuel tank (sub)
•  Disconnected hose between fuel tank (main) and fuel tank (sub)
•  Instrument cluster malfunction
•  Body control module (BCM) malfunction
•  PCM malfunction
System wiring diagram
•  Not applicable
Connector diagram
•  Not applicable

Diagnostic Procedure

Step

Inspection

Results

Action
1
VERIFY FUEL LEVEL ON FUEL GAUGE
•  Verify the fuel level on the fuel gauge.
•  Does the fuel level indicate near E?
Yes
Explain to the customer that a lack of fuel is the cause.
Complete the symptom troubleshooting.
No
Go to the next step.
2
INSPECT BATTERY FOR MALFUNCTION
•  Inspect the applicable part.
•  Is the part normal?
Yes
Go to the next step.
No
Recharge or replace the battery and perform the repair completion verification.
(See BATTERY RECHARGING [(E)].)
(See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
(See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G (WITHOUT CYLINDER DEACTIVATION (E))].)
3
VERIFY PCM DTC
•  Perform the DTC inspection for the PCM.
•  Are any DTCs displayed?
Yes
Repair the malfunctioning location according to the applicable DTC troubleshooting.
(See DTC TABLE [PCM (SKYACTIV-G (E))].)
No
Go to the next step.
4
VERIFY BODY CONTROL MODULE (BCM) DTC
•  Perform the DTC inspection for the body control module (BCM).
•  Are any DTCs displayed?
Yes
Repair the malfunctioning location according to the applicable DTC troubleshooting.
(See DTC TABLE [BODY CONTROL MODULE (BCM) (E)].)
No
Go to the next step.
5
INSPECT INSTRUMENT CLUSTER FOR MALFUNCTION
•  Inspect the applicable part.
•  Is the part normal?
Yes
Go to the next step.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
(See INSTRUMENT CLUSTER REMOVAL/INSTALLATION.)
6
PURPOSE: VERIFY IF FUEL IN FUEL TANK IS DIRTY
•  Remove the fuel gauge sender unit (sub).
•  Inspect for dirty fuel.
•  Can any dirt be visually verified?
Yes
Clean the inside of the fuel tank and replace the fuel gauge sender unit and the fuel pump unit.
(See FUEL PUMP UNIT REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
(See FUEL PUMP UNIT REMOVAL/INSTALLATION [SKYACTIV-G (WITHOUT CYLINDER DEACTIVATION (E))].)
(See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [(E)].)
No
Go to the next step.
7
PURPOSE: VERIFY FUEL GAUGE SENDER UNIT (SUB) FILTER CONDITION
•  Visually verify if the fuel gauge sender unit (sub) filter is clogged.
•  Is the part normal?
Yes
Go to the next step.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
(See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [(E)].)
8
PURPOSE: INSPECT FUEL GAUGE SENDER UNIT FOR MALFUNCTION
•  Inspect the fuel gauge sender unit (main and sub).
•  Is the part normal?
Yes
Go to the next step.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
(See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [(E)].)
9
PURPOSE: VERIFY CONDITION INSIDE FUEL TANK
•  Remove the fuel pump unit.
•  Perform the following inspections.
―  Poor connection of hose between fuel tank (main) and fuel tank (sub)
―  Breakage or bending of hose between fuel tank (main) and fuel tank (sub)
•  Are all the items normal?
Yes
Go to the next step.
No
Replace the fuel tank and perform the repair completion verification.
(See FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
(See FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-G (WITHOUT CYLINDER DEACTIVATION (E))].)
10
PURPOSE: INSPECT HOSE BETWEEN FUEL TANK (MAIN) AND FUEL TANK (SUB) FOR MALFUNCTION
•  Perform the following procedure.
1.  Remove the fuel tank (main) quick release connector and the fuel tank (sub) quick release connector.
2.  Verify the airflow by blowing air through the hose.
•  Is there any clogging in the hose?
Yes
Repair or replace the malfunctioning location and perform the repair completion verification.
(See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [(E)].)
No
Go to the next step.
11
PURPOSE: INSPECT FUEL PUMP UNIT FOR MALFUNCTION
•  Install the fuel pump unit.
•  Inspect the fuel pump unit.
•  Is the part normal?
Yes
Go to the next step.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
(See FUEL PUMP UNIT REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
(See FUEL PUMP UNIT REMOVAL/INSTALLATION [SKYACTIV-G (WITHOUT CYLINDER DEACTIVATION (E))].)
Repair completion verification 1
VERIFY THAT VEHICLE IS REPAIRED
•  Install/connect the part removed/disconnected during the troubleshooting procedure.
•  Has the malfunction symptom been eliminated?
Yes
Complete the symptom troubleshooting. (Explain contents of repair to customer)
No
Refer to the controller area network (CAN) malfunction diagnosis flow to inspect for a CAN communication error.
(See CONTROLLER AREA NETWORK (CAN) MALFUNCTION DIAGNOSIS FLOW [(E)].)
•  If the CAN communication is normal, perform the diagnosis from Step 1.
―  If the malfunction recurs, go to the next step.
Repair completion verification 2
VERIFY IF MALFUNCTION IS CAUSED BY NOT PERFORMING PCM REPROGRAMMING
•  Verify repair information and verify that there is a new calibration in the PCM.
•  Is there a new calibration in the PCM?
Yes
Perform the PCM reprogramming and verify if the malfunction symptom was corrected.
•  If the malfunction recurs, replace the PCM.
No
Replace the PCM.
(See PCM REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
(See PCM REMOVAL/INSTALLATION [SKYACTIV-G (WITHOUT CYLINDER DEACTIVATION (E))].)