Help! Weird-Faulty Fuel Level Readings

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Okay,

Before I go on a spending spree on parts I need advice:

Vehicle: 1998 Camaro 3800 V6
Tank Capacity: 15.5 gallons
"Full Reading - 1st Pump "Click" ~ 12 gallons

The fuel level indicator is off! For example if the tank reads empty (red line) and I add 4 gallons ... The fuel level indicator reads 3/4 tank full!!! Or if I add 5 etc it will read FULL! So if I keep driving maybe 20-30mins later it will or will not correct to 1/4 tank etc. Or usually I will restart the car and suddenly it will be reading the expected amount again around the empty fuel level. Something is definately off calibration
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All this time I thought my fuel economy was #@$%!, so now maybe that is not the case.

(Now when the car was normal 3 gallons would read 1/4 etc to a T.)


Okay so here is the flow chart. My assumption is that the Instrument Cluster is the lowest chance of being the culprit here. If I buy a complete Fuel sender assembly (Bosch, AC Delco) from rock auto etc does it include the pump, float, level sensor etc all in one? Could a faulty ground cause this as well?

The sending assembly itself is around 250-350$ My worry is labor to drop the tank
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Thanks for any advice.
 
I just ran into this issue with my mother-in-law's '99 GMC truck, and posted something in another thread.

Before you start throwing money at parts (which can get very expensive), I'd run a tank or two of the recommended dosage of Techron Plus additive. My MIL's gauge would constantly bounce up and down, fuel light blinking on/off, no matter how much gas was in the tank. The Techron Plus advertises that this erratic behavior can be caused by deposits (I think sulfur) from sub-par gas on the fuel sending unit contacts. Chevron claims the Techron Plus can remove these deposits, restoring proper functioning. At $7/bottle, I tried two in my M-I-L's truck (her 25 gal tank required two bottles, you may get by with one). Within 100 miles, her gauge suddenly began reading correctly, without the erratic jumping. I can't guarantee it will work on yours, but it saved my M-I-L $274 for the new fuel pump/FSU assembly. And the Techron was on special at Advance Auto 2 for one. So, a $7 fix.
There may be other gas additives that can do the same type of cleaning of the contacts on the FSU. But the Techron was available, and the Plus even has the claim right on the bottle. I don't know about the previous version of Techron removing these deposits, or if/how the "Plus" is different. But it would definitely be worth a shot, plus the added benefit of a fuel system cleaning.

In answer to your question about a ground causing it, that is a possibility. It would be more of a concern if you lived up north with salted roads. I don't know how your Camaro's ground system works, but I would think a bad ground for the FSU would also cause issues with other parts, as grounds are often shared.

Here's what I would do in your situation:
1) Run a tank or two with recommended dosage of Techron Plus
2) Pull codes from your ECU (being a '98, it is OBDII compliant). Even with no "Check Engine Light" on, there may be stored codes for a problem. I don't know how easy the Camaro is to pull codes, but my '97 Maxima only requires a screwdriver and watching for blinks. Easy and free. Also pretty thorough throughout the car's various systems. If yours is hard to access/get codes from, move it to number 3.
3) Visually check all of your ground connections, especially any near the tank/backend. Also around your fuse and relay boxes under the hood. But if one of those is bad, I'd guess you'd have other issues.
4) Test your fuel pump/FSU if testable. But this would probably require dropping the tank, which on your car would be a labor intensive job (you need to remove the rear axle I believe).

Here's info from Chevron's site on the FSU issue and Techron:

New 'clean' gasolines can cause fuel gauge malfunction

The Problem:
Certain residual sulfur species found at very low levels in many of todays highly refined gasolines can form corrosive deposits on reactive silver-based fuel sending unit (FSU) components used in many makes of automobiles. The FSU, located inside the fuel tank, reads the fuel level and electronically sends a signal to the fuel gauge.

How sulfur corrosion can cause your vehicle's fuel gauge to malfunction (false reading).
This corrosive deposit can disrupt the electrical performance of the FSU and lead to either erratic operation or complete failure of the FSU, often resulting in artificially low or high (empty or full) fuel level readings on the fuel gauge seen by the driver. An erroneous high (or full) fuel gauge reading could lead to the motorist inadvertently running out of fuel and create a potentially dangerous situation.

The problem is best viewed in medical terms: acute and chronic in nature

Acute: problems occur when the occasional batch of off-specification, high sulfur refinery gasoline leads to extensive erratic FSU operation across a region. The problem can occur in a single tank of gas.
Examples: Louisiana, Florida, Memorial Day, 2004; Erie, PA, Louisville, KY, Canada

Chronic: problems occur after long-term exposure to low-grade sulfur contamination in a fuel, which frequently leads to premature erratic behavior of the FSU at some point.
Examples: New Mexico and Arizona, 2004 and 2005

Higher temperatures play a vital roll in how severely an FSU is damaged by a harmful sulfur-containing gasoline.

FSU failures typically require the complete replacement of the sending unit at considerable expense to either the vehicle manufacturer or the vehicle owner. This repair can cost from $400 to over $1000.

There is strong automaker awareness, as virtually all automakers have been impacted: recalls, warranty repairs, safety concerns and product reputation. Some automakers are beginning to phase out reactive silver-based FSU components at significant expense. However, reactive silver-based FSU components have been used since the late 80's, so a 15 year-plus vehicle population is still exposed.

The Solution:
TECHRON® Concentrate Plus is one of the most advanced fuel system cleaning technologies available in today's market, and many automakers prescribe it routinely as their solution to all fuel deposit-related driveability problems.

One treatment with TECHRON® Concentrate Plus can help:

Clean corrosive sulfur deposits from fuel gauge sensors
Restore operation of sulfur contaminated fuel gauge sensors
Prevent harmful sulfur species from attacking sensitive electronic fuel sending units
Protect the FSU against malfunction by coating all metal surfaces of the fuel system


Hope this helps.

Dave
 
Thanks I will try Chevron Techcron 20oz added to a 12 gallons tommorrow for a 130mile highway round trip. I will repeat this off course. The final weapon will be the expensive BG44K to a 1/4 tank. I think your on to something as my car has even developed a weird knocking hear only through the exhaust for once or twice after a cold start. There could be some fouling by bad Your post will also provide ammo for me if I show up to speak to a service advisor. Funny, I thought my near constant of Shell, Texaco, Sunoco would keep me clean. I feel dirty now. If your theory is correct at least we can not blame the Ethanol for the problems
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Here is the fuel sender assembly, is the pump, fuel level sensor, and float included in this? (the rod thingy)

Bosch: 472$
AC Delco: 342$

http://198.208.187.182/internet/PartImage.jsp?mfgname=ACDELCO&prodlinecd=43&acpartnbr=MU115

http://info.rockauto.com/Bosch/Detail.html?67354.jpg

Here is what would make me mad ... if I buy the AC delco unit and it says "Bosch" on it! I have seen Bosch O2 etched with "AC" on them before
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The other question is whether Bosch or AC Delco is better minus the price differential. Fuel pumps are absolute reliability peices
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Thanks!
 
Here's a link to the AutoZone pic of the fuel pump/FSU assembly: http://autozone.com/servlet/UiBroker?For...23d801cee97.jsp
In your links, the Bosch unit looks like it includes the entire assembly (fuel pump, FSU, etc). The AC pic looks like it is only the FSU, as I don't see a pump with it's associated lines in it when compared to AutoZone's pic. If you do need to get one (meaning the Techron doesn't fix it), I'd ask about what's included when you buy it. Also check Advance Auto, because my M-I-L's for her '99 GMC 5.3 liter truck was only $274 for the complete assembly. Yours may be similarly priced. I didn't ask what brand because I wasn't purchasing it at the time. Both Bosch and AC are reputable brands, so I wouldn't hesitate to run either one. It would come down to warranty and price between those two.

I would definitely give the Techron a little while to work. Hopefully it is just the FSU contacts corroded, and Techron will clean them off. My M-I-L's still hasn't acted up since after the first 100 miles or so with the Techron.

Sounds like you're using quality brand gas, but even they can cause problems sometimes. There are a lot of variables in the fuel delivery to the station that may be beyond their control. They may have old tanks, not change their filters, or the delivery truck may have been contaminated somehow. This is one reason I try to run Techron in my personal vehicles every OCI or so. Hopefully it is preventing any problems from forming (although I don't have absolute, scientifically verifiable proof either way). So far, I've never had a fuel pump issue in the many vehicles I've owned.

Hope this helps.

Dave
 
I ran 4-5 tanks each with one bottle of Techron. The error has "improved" a bit but there is still error readings higher than normal! In other words if I add 2-3 gallons of fuel (at redline-empty) it will read 1/2 tank or less instead of a full tank (as it did a few weeks ago) *lol* I will also have the grounds checked ... if I shut of and restart the engine I will often soon after get a lower possibly corrected level reading. Lesson learned I will never run cheap fuel again, also will go back to running Redline S1 * Chevron Techron Concentrate every 3k or less.

I talked to a local Technical College with a GM sponsored automotive tech program. They said they would use the car to teach and replace the FMU. Down side is next fuel systems class is next year (fall). That would save me a ton on labor if checking/cleaning and tightening the grounds fails.
 
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