FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
Courtesy of Operation CHARM: Car repair manuals for everyone.
Home >> Chevrolet >> 2013 >> Volt L4-1.4L Elect >> Repair and Diagnosis >> Body and Frame >> Locks >> Testing and Inspection >> Fuel Filler Door Release Malfunction

Fuel Filler Door Release Malfunction




Fuel Filler Door Release Malfunction

Diagnostic Instructions

* Perform the Diagnostic System Check - Vehicle Diagnostic System Check - Vehicle prior to using this diagnostic procedure.

* Review Strategy Based Diagnosis Strategy Based Diagnosis for an overview of the diagnostic approach.

* Diagnostic Procedure Instructions Diagnostic Procedure Instructions provides an overview of each diagnostic category.

Diagnostic Fault Information






Circuit/System Description

The Hybrid Powertrain Control Module 2 monitors the voltage values of the fuel fill door open request wake-up signal circuit and the fuel door request signal circuit. When the Refuel Request Switch is pressed, the two switch contacts close. This provide B+ to the Wake-up Circuit input of the Hybrid Powertrain Control Module 2 and lowers the voltage on the fuel door request signal circuit input to the Hybrid Powertrain Control Module 2. The Hybrid Powertrain Control Module 2 detects the voltage on the signal circuits and commands the fuel system to vent and sends a serial data message to the driver information center to display the Wait to Refuel message. The Hybrid Powertrain Control Module 2 then energizes the fuel door lock/unlock actuator to unlock the fuel door.

Reference Information

Schematic Reference

Release Systems Schematics Release Systems Schematics

Connector End View Reference

Component Connector End Views Hybrid/EV Battery Pack X1

Description and Operation

Fuel Fill Door Description and Operation Fuel Fill Door

Electrical Information Reference

* Circuit Testing Circuit Testing

* Connector Repairs Connector Repairs

* Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections

* Wiring Repairs Wiring Repairs

Scan Tool Reference

Control Module References Programming and Relearning for scan tool information

Circuit/System Verification

1. Vehicle in Service Mode.

2. Verify the M97 Fuel Door Lock Actuator will LOCK and UNLOCK when commanding the Fuel Fill Door Lock to Lock and Unlock with a scan tool.

• If the LOCK and UNLOCK function for the M97 Fuel Door Lock Actuator does not work
Refer to Circuit/System Testing - Fuel Door Release Inoperative.

• If the LOCK and UNLOCK function for the M97 Fuel Door Lock Actuator works

3. Verify the M97 Fuel Door Lock Actuator will UNLOCK when pressing the S117 Refuel Request Switch.

• If the UNLOCK function for the M97 Fuel Door Lock Actuator does not work
Refer to Circuit/System Testing - Refuel Request Switch Inoperative When Module Is Awake

• If the M97 Fuel Door Lock Actuator UNLOCKS

4. Vehicle OFF, it may take up to 2 minutes for the Hybrid Powertrain Control Module 2 to enter the sleep mode.

5. Verify the M97 Fuel Door Lock Actuator will UNLOCK when pressing the Refuel Request Switch.

• If the UNLOCK function for the M97 Fuel Door Lock Actuator does not work
Refer to Circuit/System Testing - Refuel Request Switch Inoperative When Module Is Asleep

• If the M97 Fuel Door Lock Actuator UNLOCKS

6. All OK.

Circuit/System Testing

Fuel Door Release Inoperative

1. Vehicle OFF, disconnect the harness connector at the M97 Fuel Door Lock Actuator.

2. Test for greater than 10 V between the control circuit terminal 1 and ground.

• If 10 V or less

1. Vehicle OFF, disconnect the harness connector at the K114B Hybrid Powertrain Control Module 2.

2. Test for infinite resistance between the control circuit and ground.

• If less than infinite resistance, repair the short to ground on the circuit.

• If infinite resistance

3. Test for less than 2 ohms in the control circuit end to end.

• If 2 ohms or greater, repair the open/high resistance on the circuit.

• If less than 2 ohms, replace the K114B Hybrid Powertrain Control Module 2.

• If greater than 10 V

3. Test for greater than 10 V between the control circuit terminal 2 and ground.

• If 10 V or less

1. Vehicle OFF, disconnect the harness connector at the K114B Hybrid Powertrain Control Module 2.

2. Test for infinite resistance between the control circuit and ground.

• If less than infinite resistance, repair the short to ground on the circuit.

• If infinite resistance

3. Test for less than 2 ohms in the control circuit end to end.

• If 2 ohms or greater, repair the open/high resistance on the circuit.

• If less than 2 ohms, replace the K114B Hybrid Powertrain Control Module 2.

• If greater than 10 V

4. Connect a test lamp between control circuit terminal 1 and control circuit terminal 2, Vehicle in Service Mode.

5. Verify the test lamp turns ON when commanding the LOCK and UNLOCK states with a scan tool.

• If the test lamp remains OFF during either of the commands

1. Vehicle OFF, disconnect the harness connector at the K114B Hybrid Powertrain Control Module 2. Vehicle in Service Mode

2. Test for less than 1 V between each control circuit and ground.

• If 1 V or greater, repair the short to voltage on the circuit.

• If less than 1 V replace the K114B Hybrid Powertrain Control Module 2

• If the test lamp turns ON during each of the commands

6. Test or replace the M97 Fuel Door Lock Actuator.

Refuel Request Switch Inoperative When Module Is Awake

1. Vehicle OFF, disconnect the harness connector at the S117 Refuel Request Switch. It may take up to 2 minutes for all vehicle systems to power down.

2. Test for less than 10 ohms between the low reference circuit terminal 6 and ground.

• If 10 ohms or greater

1. Disconnect the harness connector at the K114B Hybrid Powertrain Control Module 2

2. Test for less than 2 ohms in the low reference circuit end to end.

• If 2 ohms or greater, repair the open/high resistance in the circuit.

• If less than 2 ohms, replace the K114B Hybrid Powertrain Control Module 2.

• If less than 10 ohms

3. Vehicle in Service Mode, test for 4.8-5.2 V between the 5 V reference circuit terminal 3 and ground.

• If less than 4.8 V

1. Vehicle OFF, disconnect the harness connector at the K114B Hybrid Powertrain Control Module 2.

2. Test for infinite resistance between the 5 V reference circuit and ground

• If less than infinite resistance, repair the short to ground on the circuit.

• If infinite resistance

3. Test for less than 2 ohms in the 5 V reference circuit end to end.

• If 2 ohms or greater, repair the open/high resistance in the circuit.

• If less than 2 ohms, replace the K114B Hybrid Powertrain Control Module 2.

• If greater than 5.2 V

1. Vehicle OFF, disconnect the harness connector at the K114B Hybrid Powertrain Control Module 2, Vehicle in Service Mode.

2. Test for less than 1 V between the 5 V reference circuit and ground.

• If 1 V or greater, repair the short to voltage on the circuit.

• If less than 1 V, replace the K114B Hybrid Powertrain Control Module 2.

• If between 4.8-5.2 V

4. Test or replace the S117 Refuel Request Switch.

Refuel Request Switch Inoperative When Module Is Asleep

1. Vehicle OFF, disconnect the harness connector at the S117 Refuel Request Switch. Vehicle in Service Mode.

2. Verify a test lamp illuminates between the B+ circuit terminal 1 and ground.

• If the test lamp does not illuminate and the circuit fuse is good

1. Vehicle OFF.

2. Test for less than 2 ohms in the B+ circuit end to end.

• If 2 ohms or greater, repair the open/high resistance in the circuit.

• If less than 2 ohms, verify the fuse is not open and there is voltage at the fuse.

• If the test lamp does not illuminate and the circuit fuse is open

1. Vehicle OFF.

2. Test for infinite resistance between the B+ circuit and ground.

• If less than infinite resistance, repair the short to ground on the circuit.

• If infinite resistance

3. Disconnect the X2 harness connector at the K114B Hybrid Powertrain Control Module 2.

4. Test for infinite resistance between the signal circuit terminal 2 and ground.

• If less than infinite resistance, repair the short to ground on the circuit.

• If infinite resistance, replace the K114B Hybrid Powertrain Control Module 2.

• If the test lamp illuminates

3. Vehicle OFF, connect the harness connector at the S117 Refuel Request Switch. Disconnect the X2 harness connector at the K114B Hybrid Powertrain Control Module 2.

4. Connect a test lamp between the signal circuit terminal 7 and ground.

5. Verify the test lamp turns ON and OFF by pressing the S117 Refuel Request Switch.

• If the test lamp is always OFF

1. Vehicle OFF, disconnect the harness connector at the S117 Refuel Request Switch.

2. Test for infinite resistance between the signal circuit and ground.

• If less than infinite resistance, repair the short to ground on the circuit.

• If infinite resistance

3. Test for less than 2 ohms in the control circuit end to end.

• If 2 ohms or greater, repair the open/high resistance in the circuit.

• If less than 2 ohms, test or replace the S117 Refuel Request Switch.

• If the test lamp is always ON

1. Vehicle OFF, disconnect the harness connector at the S117 Refuel Request Switch, Vehicle in Service Mode.

2. Test for less than 1 V between the control circuit and ground.

• If 1 V or greater, repair the short to voltage on the circuit.

• If less than 1 V, test or replace the S117 Refuel Request Switch.

• If the test lamp turns ON and OFF

6. Replace the K114B Hybrid Powertrain Control Module 2.

Component Testing

Fuel Door Open Request Switch

1. Vehicle OFF, disconnect the harness connector at the S117 Refuel Request Switch.

2. Test for infinite resistance between the signal terminal 2 and the B+ terminal 1 with the switch in the open position.

• If less than infinite resistance
Replace the S117 Refuel Request Switch.

• If infinite resistance

3. Test for less than 3 ohms between the signal terminal 2 and the B+ terminal 1 with the switch in the closed position.

• If 3 ohms or greater
Replace the S117 Refuel Request Switch.

• If less than 3 ohms

4. All OK

Fuel Door Lock Actuator

1. Vehicle OFF, disconnect the harness connector at the M97 Fuel Door Lock Actuator.

2. Install a 25 A fused jumper wire between one of the control terminals and 12 V. Momentarily install a jumper wire between the other control terminal and ground. Reverse the jumper wires at least two times, the M97 Fuel Door Lock Actuator should perform the LOCK and UNLOCK function.

• If the actuator does not perform the LOCK and UNLOCK function
Replace the M97 Fuel Door Lock Actuator.

• If the actuator performs the LOCK and UNLOCK function

3. All OK

Repair Instructions

Perform the Diagnostic Repair Verification Verification Tests after completing the diagnostic procedure.

* Fuel Tank Filler Door Lock Actuator Replacement Fuel Tank Filler Door Lock Actuator Replacement

* Fuel Tank Filler Door Lock Release Switch Replacement Fuel Tank Filler Door Lock Release Switch Replacement

* Control Module References Programming and Relearning for the Hybrid Powertrain Control Module 2 replacement, programming and setup

pro multis Credits:Operation CHARM About Operation CHARM