Fuel level reading wrong?

Tiny
JR47
  • MEMBER
  • 2005 PONTIAC GRAND PRIX
  • 3.8L
  • V6
  • 2WD
  • AUTOMATIC
  • 203,466 MILES
My fuel level rose from 3/4 to almost full while driving for about 40 minutes. I did ask a previous question about a gurgling/bubbling sound coming from the gas tank and was told to replace the fuel pump assembly so I did which solved the sound issue and during that time I pulled 5 gallons of gas from the tank with around 2 to 3 gallons left in it before installing the new assembly into the tank and putting everything back onto the car and put that same 5 gallons back into the car which is when the gauge went to 3/4. Drove to the next town over thats when the fuel level started going up and fuel range went from 190 to 230. So stopped at the gas station and fuel level was reading almost full at the time and was only able to put a little over 3 gallons in it then the level went back to 3/4 after starting the vehicle.

Sorry for the long and possibly confusing description but just wondering if I got a bad fuel pump assembly or is there something else I should be looking at or checking.
Saturday, July 22nd, 2023 AT 11:07 PM

7 Replies

Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,689 POSTS
Hi,

Did this happen prior to the replacement? Did you have any trouble installing the new assembly with the float?

The float is attached to a rheostat. The rheostat is a resister that changes the voltage based on the float's position in the tank. If anything, that is what I would think could cause this unless we have a wiring issue.

If you look below, I attached a pic of the assembly. I circled the rheostat also known as a level sensor. Could the float arm have gotten bent when installing the assembly into the tank?

Let me know.

Joe

See pic below.
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Sunday, July 23rd, 2023 AT 8:00 PM
Tiny
JR47
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Didn't have any trouble installing the new assembly, it went in fairly easy. When I bought the car, it had less than a quarter tank of fuel, so I put gas in it which I was only able to get 7 gallons in it before the pump stopped me from putting any more in and it only went to half a tank on the gauge.

I don't know if it could cause a wiring issue but the old assembly had a ton of dirt and dust on top of it which I did clean and vacuum up before removing.
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Sunday, July 23rd, 2023 AT 11:35 PM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
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Hi,

It could be a ground issue. If there is excessive resistance, it can change the signal to the PCM, which then sends the signal to the instrument cluster (fuel gauge).

Do me a favor. At the fuel pump connector (black connector/4 pin), I need you to check for continuity to ground. If you look below, I attached a pic of the connector. We need to check pins C and D.

Pin C should have ground at all times. Pin D will have it with the key on. Check that and let me know what you find or if there is excessive resistance in the wire.

Let me know.

Joe

See pic below.
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Monday, July 24th, 2023 AT 8:49 PM
Tiny
JR47
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That'll have to wait till the weekend but if this info is any help, I was able to put 10 gallons of fuel in without issue and the fuel gauge went from reading almost full before filling, down to a quarter tank after doing so.
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Tuesday, July 25th, 2023 AT 1:58 AM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,689 POSTS
Hi,

That almost sounds like something is wired backward. Were there any issues with the connector or wiring when the work was done?

Let me know.

Joe
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Tuesday, July 25th, 2023 AT 8:33 PM
Tiny
JR47
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That's kind of what I was thinking with how everything has been playing out with it. I haven't added any fuel since and the level on the gauge has gone up so seems like something is possibly backwards. I don't recall there being any issues with connector's or any wiring when doing the work but I can check and there's no access panel in the trunk so I'll have to lower the tank again to check the connections on top of the assembly.
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Wednesday, July 26th, 2023 AT 2:34 AM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,689 POSTS
Hi,

If you have to go through that much, return the pump as faulty and try a different one. There could be an issue with the new rheostat.

Let me know what you find. Also, make sure to check the ground pins when it is out. Move the wiring around when checking for continuity to see if it varies.

Take care,

Joe
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Wednesday, July 26th, 2023 AT 7:41 PM

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