1991 Plymouth Voyager Fuel Guage Intermittant -

Tiny
MODELCITIZEN
  • MEMBER
  • 1991 PLYMOUTH VOYAGER
  • 6 CYL
  • FWD
  • AUTOMATIC
  • 139,000 MILES
My '91 Plymouth Grand Voyager SE, 3.3L, has a fuel guage reading that is erratic, sometimes displaying accurate levels of fuel, other times displaying different but incorrect levels of fuel in the tank. Sometimes the needle doesn't even lift off the "0" stop (which immediately trips the low fuel indicator and audio alert). All of the other guages seem to be working fine when this problem arises. Is this an indicator of a faulty sender unit, or more likely a wiring problem, if the latter, where to look and in what order?

Thanks,
StillVoyaging
Monday, March 9th, 2009 AT 11:29 AM

2 Replies

Tiny
ZACKMAN
  • MECHANIC
  • 4,202 POSTS
That does sound like faulty sending unit.
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Wednesday, March 11th, 2009 AT 12:23 AM
Tiny
CARADIODOC
  • MECHANIC
  • 33,797 POSTS
Very common problem. The contacts have lost pressure on the sending unit. It's clipped to the side of the fuel pump assembly. A replacement sending unit WILL develop the same problem.

The most effective, permanent repair involves dropping the tank, lifting the pump up just enough to bend a plastic clip to allow the float arm to be slid off, then bending the contacts to have more pressure. Snap the float arm back on and reinstall the pump and tank.

Performed this repair many times. Takes about an hour when you have all the proper tools at hand. Once you know what you're looking for, you don't even have to pull the filler tube out of the tank. Don't attempt this until the tank is near empty so it's easier to handle.

Caradiodoc
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Saturday, March 21st, 2009 AT 5:05 AM

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