Inaccurate Fuel Gage and / or DTC P0461 - keywords cluster empty ipc

This PI was superceded to include customer habit of topping off tank. Please discard PIC4878A.

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Customer may report the fuel gage is inaccurate. DTC P0461 may be present.

Engineering has found over 80% of the returned fuel level sender cards had no trouble found.

Interference is suspected between the end of the float arm where it is attached to the sending unit and the convoluted tubing that is part of the sending unit. To inspect for the potential interference it is necessary to compress the fuel sending unit on the bench to the same height as it is compressed in the fuel tank.

If you see the potential for interference when compressing the assembly, please take a picture if possible and send it in using the electronic Field Product Reporting process per TSB 02-00-89-002G, then repair/replace the MRA [Module Reservoir Assembly-(module kit, f/tnk f/pmp)] as necessary.

Note: DTC P0461 can also be customer induced by refueling after only 50 or 60 miles of travel or less. There is currently no software or calibration tool to directly address the situation where a vehicle is constantly topped off after driving short distances.

Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed.