Fuel Gauge Erratic In Freezing Temperatures P0463 - keywords cluster cold flat gage inaccurate intermittent IPC level sender

This PI was superseded to update engines codes and to add a parts application chart. Please discard PIT4294C.

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

The fuel gauge is erratic and displays the incorrect fuel level in freezing weather.

Example concerns:

1. The fuel tank is ¾ full. While driving, the fuel gauge gradually starts to display a lower fuel level, beyond the reduction that is due to engine fuel consumption. The fuel gauge may subsequently recover to an accurate fuel level display.
2. After being parked in below-freezing weather, the vehicle is started and the fuel gauge displays a reading of "E". With driving, the gauge reading may slowly recover towards the actual fuel level. If the ignition is then cycled, the fuel gauge may now display the actual fuel level.

Note:  A P0463 Diagnostic Trouble Code may or may not be set. If it is set, the fuel gauge is commanded to "E".

The condition is related to excess water in non-ethanol fuel at below-freezing temperatures causing ice crystals in the fuel which interferes with the proper operation of the fuel level sender.

Updated fuel level sensors, with a shield to help protect from icing, are now available. Use the chart below to obtain the updated part:

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.