Erratic fuel gauge?

Tiny
DGUNN427
  • MEMBER
  • 2000 CHEVROLET SILVERADO
  • 5.3L
  • V8
  • 2WD
  • AUTOMATIC
  • 130,000 MILES
It would jump from reading full, to reading empty, to reading correct. Most of the time it read empty. The truck ran fine in spite of the fuel gauge. The sending unit is part of the fuel pump so a purchased a new fuel pump, lifted off the bed to access the top of the gas tank and traded out the pump and sending unit. My old pump had two electrical connections and while the new pump had two connections as well one was a different connector which required cutting and splicing into the existing wiring. Not a big deal. I spliced in the new connector and installed the new pump. Time to test the installation. Two things occurred. First was that turning the key would turn off all power to the truck, I would disconnect then reconnect the battery and everything would reset, but again every time I turned the key it was like the truck would go completely dead. By mistake, after jumping in the truck I pumped the accelerator a few times, then turned the key and this time when I turned the key the truck cranked. It didn’t want to run at first, but I attributed that to the pump needing to refill the lines to the engine and getting air out of the lines. Eventually it ran and then started up consistently time after time. Now that the truck was back to running, I have my second issue. The fuel gauge is still not working; however, it is a different issue than where my issue started. Before the gauge was erratic, now it is just on empty. (Well, way below empty). (Confirmed The tank is not empty; it is maybe 3/4 full). The gauge reads almost 180 degrees around from where it should be. The pointer on the gauge is pointing down, (should be pointing up) below the increments marked on the gauge. Do I have a faulty sending unit? Do I have a wiring issue? I checked my spliced connections, and they look tight and per the included instructions. I checked fuses and all seem good. I pulled the pump and sending unit out of the tank again. What can I trouble shoot next? Thanks.
Sunday, May 21st, 2023 AT 9:33 PM

6 Replies

Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 108,217 POSTS
Hi,

If the gauge is basically 180 degrees off, it sounds like you switched the two wires for the level sensor. One is the power supply from the PCM and the other is the signal return.

At the connection, do you remember a purple wire and an orange with a black tracer? If you disconnect the two, the purple should supply power and the orange, black is the return, so no power should be present. If you switched them, the power is going through the rheostat backward. It would be like changing the polarity and could explain why the gauge is the opposite of what it should be.

Let me know.

Joe

See pic below.
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Sunday, May 21st, 2023 AT 9:50 PM
Tiny
DGUNN427
  • MEMBER
  • 4 POSTS
Thanks Joe. I checked the wires yesterday, but I’ll do that again. I suppose I can check the purple for voltage when the key is on? The wires were grey, black, purple, and black/orange stripe. I matched them up with the new pigtail that was included with the fuel pump. With the gauge pegged so far out of whack I was wondering if something isn’t reversed. I’ll look it over again today just to check. Thanks. David.
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Monday, May 22nd, 2023 AT 4:29 AM
Tiny
DGUNN427
  • MEMBER
  • 4 POSTS
On my way out the door to work I looked, and the wire colors all matched. Not sure that is visible in my photo. Also attached is the diagram from the fuel pump instructions. It seems to match up. (Combination 1). Thanks.
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Monday, May 22nd, 2023 AT 5:25 AM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 108,217 POSTS
Hi,

When you turn the key off, does the fuel gauge return to empty?

Let me know.

Joe
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Monday, May 22nd, 2023 AT 3:08 PM
Tiny
DGUNN427
  • MEMBER
  • 4 POSTS
The key, or power didn't affect the gauge, however, the problem seems to be solved. I opened up the instrument cluster. The needle for the gauge had flipped around and was stuck facing down. I gently pushed the needle to where it should generally be on the gauge. Once everything was reconnected the gauge seems to be reading correctly.
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Monday, May 22nd, 2023 AT 6:43 PM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 108,217 POSTS
Hi,

That is good news. LOL I was thinking the polarity was reversed causing the needle to turn in the opposite direction. I like your fix better. LOL

If anything changes, let me know.

Take care,

Joe
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Monday, May 22nd, 2023 AT 7:35 PM

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