Customer concern: Fuel gauge incorrect reading.
Phenomenon description:
During inspection observed the fuel gauge indicates ¾ level.
Performed self diagnosis test of the combination meter it’s found ok.
We test drive the vehicle not observed any fuel gauge erratic.
Not observed any underneath damage on the fuel tank.
Inspection and diagnosis carried out:
Further inspection without removing the fuel pump, checked sender unit resistance found 145.5Ω
After removing the fuel pump found fuel was full in the fuel tank.
Removed and fixed fuel pump found symptom still same and also not observed any abnormality
inside the fuel tank.
Then checked fuel sender unit resistance as per specific height – found OK
However we replaced fuel pump and tested the vehicle symptom still persist.
Further we removed fuel tank and compared with known good vehicle found 3.4MM different
between neck to bottom of fuel tank is different