96 Tahoe Fuel gauge/sender

[Andrew R]

I have owned my truck for over 4 years now and the fuel gauge has never worked. After 4 months of owning it I hit a large pothole in the road and the gauge went to half a tank(which seemed accurate for my miles on the tank). About 5 minutes later I hit another pothole and it went back to being pegged at full.

Fast forward to today.....I replaced the fuel pump/sending unit with a new delphi unit. I turned to key on and it didn't budge!

Ive tried three different clusters and all of them do the same thing...



I'm at a complete loss.

 

[no cigar]

I'm jumping on this thread too...

yesterday while accelerating up an onramp to the highway under load, the truck shut off completely. Cranks solidly with no start. My fuel gauge is absolutely dead like the OP picture. Key on ign off, I can hear no pump priming or anything. Had been having a misfire and poor idle/run below 2500 RPM. Hoping it's the pump/sender module.

 

[SunlitComet]

I have owned my truck for over 4 years now and the fuel gauge has never worked. After 4 months of owning it I hit a large pothole in the road and the gauge went to half a tank(which seemed accurate for my miles on the tank). About 5 minutes later I hit another pothole and it went back to being pegged at full.

Fast forward to today.....I replaced the fuel pump/sending unit with a new delphi unit. I turned to key on and it didn't budge!

Ive tried three different clusters and all of them do the same thing...



I'm at a complete loss.

you have an open wire in the gauge circuit.

---------- Post added at 06:38 PM ---------- Previous post was at 06:36 PM ----------

I'm jumping on this thread too...

yesterday while accelerating up an onramp to the highway under load, the truck shut off completely. Cranks solidly with no start. My fuel gauge is absolutely dead like the OP picture. Key on ign off, I can hear no pump priming or anything. Had been having a misfire and poor idle/run below 2500 RPM. Hoping it's the pump/sender module.

or its connector. if yours is pegged high as well then the pump connector has an issue or the ground from the unit is broke killing off both parts of pump assembly.

 

[no cigar]

In the event that it is a pump I do have a full tank of gas, doh.

I tried siphoning yesterday but it seems like the line i was using was hitting some sort of kink or something and it wasn't going into the tank. Is there some tyupe of anti siphon device in there?

 

[no cigar]

new pump is in... still dead.

ecm-I fuse is blowing on Key-On??

 

[SunlitComet]

I am not near the service manual for about another day or two. Did it start blowing after the new pump install?

---------- Post added at 08:47 PM ---------- Previous post was at 08:46 PM ----------

Can't recall at the moment what is all fed by that fuse to troubleshoot.

 

[no cigar]

Sorry it was a busy weekend and I didn't get a chance to update. It's FIXED!

ECM-I fuse goes to injectors and ICM among some other things. Unplugged the injector and ICM harnesses and keyed on and fuse was still good. Plugged in the spider and it blew. Got the intake hat off and got the old spider out and it seems one of the injector wires rubbed on the bracket, wore clear through the sheath, and was grounding out on the bracket. It was not the Delphi unit that I paid to have installed when the new engine was put in last year so it looks like I got taken. It couldn't have been made for that bracket because those wires were in direct contact with it. Amazing that none of the others wore as well. The Delphi unit cleared the bracked with at least 1/2" of space so I feel much better. Luckily it had been warrantied by Amazon and I got a replacement months ago. Put the new one in and all misfires were cleared and she runs like a top.