1999 Chevrolet Cutaway 7.4 JFACTORY OEM SERVICE PROCEDURE

Diagnostic Procedures

  1. Perform On-Board Diagnostic (OBD) system check. See ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK under SELF-DIAGNOSTIC SYSTEM in SELF-DIAGNOSTICS INTRODUCTION article. After performing OBD system check, go to next step.
  2. Raise and support vehicle. Disconnect fuel pump harness connector. Using a test light connected to battery positive, probe both ground circuits from ECM at fuel level sensor harness connector. If test light illuminates for both circuits, go to next step. If test light does not illuminate for both circuits, go to step  8.
  3. Turn ignition on. Measure voltage between ground and fuel level input circuit at fuel level sensor harness connector (ECM side). If battery voltage is present, go to next step. If battery voltage is not present, go to step  7.
  4. Check for faulty harness connections. If a problem is found, go to step  12. If connections are okay, go to next step.
  5. Check harness between harness connector and fuel pump for opens or shorts. If a problem is found, go to next step. If harness is okay, go to step  7.
  6. Repair open or short in harness as necessary. After repairs, go to step  13.
  7. Replace fuel level sensor. After repairs, go to step  13.
  8. Repair open in ground circuit. After repairs, go to step  13.
  9. Check fuel level input circuit for a short to ground. If a problem is found, go to next step. If circuit is okay, go to step  11.
  10. Repair open or short to ground in fuel level input circuit. After repairs, go to step  13.
  11. Replace ECM. Program replacement ECM using required equipment. Ensure ECM is programed with theft deterrent system frequency code that is currently on vehicle. After repairs, go to step  13.
  12. Repair or replace terminals as necessary. After repairs, go to next step.
  13. Using scan tool, clear DTCs. Start engine and allow it to idle. Ensure engine is at normal operating temperature. Operate vehicle within conditions required for setting this DTC. Select SPECIFIC DTC function then enter this DTC. If scan tool indicates TEST RAN AND PASSED, go to next step. If scan tool does not indicate TEST RAN AND PASSED, repeat step  2.
  14. If other DTCs were present during OBD system check and have not been diagnosed, go to applicable DTC. If no other DTCs are present, system is okay.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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