Instruments - Fuel Gauge Reads Empty After Fuel Fill: Overview

20 Fuel gauge reads empty after refueling (DTCs 00438, 00771)

20 10 07

2020884/6

August 11, 2010

Supersedes Technical Service Bulletin Group 20 number 10-06 dated June 23, 2010 for reasons listed below.





Affected Vehicles





CONDITION

^ After refueling, the fuel gauge reads empty.

^ One or both of the following DTCs are stored in the instrument cluster.

^ DTC 00438 (Fuel level Sensor 2 -G169- Open/Short circuit to B+ or Short circuit to Ground).

^ DTC 00771 (Sender for fuel gauge -G- Open/Short circuit to B+ or Short circuit to Ground).

TECHNICAL BACKGROUND

Due to the unattached section of cable in the area of the 2-pin plug-in connections (inside the fuel tank) between the flange of the electric fuel pump and the fuel gauge sensors "G" or "G169", there are vibrations while driving. These vibrations cause micro movements at the pins, which lead to the formation of fretting corrosion on the pins. As a result, there are conductivity interruptions at the pins and finally spoadic or static failure of the tank display.

PRODUCTION SOLUTION

Two-pin plug-in connections are stabilized during production of model year 2008.





WARRANTY





REQUIRED PARTS AND TOOLS

ADDITIONAL INFORMATION

All parts and service references provided in this TSB are subject to change and/or removal. Always check with your Parts Department and service manuals for the latest information.