Fuel guage problem on a 98 Chevrolet Malibu?

Question

I am an ASE certified mechanic. I relaced the upper and lower intake manifold gaskets in a 98 Chevrolet Malibu, with a 3.1.
We all know these had a problem from the get go. After replacing the gaskets, the fuel guage went all the way around
and pegged at the BOTTOM side of the stop. Any ideas what
caused this, and how to fix? I haven't had a guage act like this before!

Answer 1

All gauges are in a balance circuit, variation coming from resistance in the sender. Older units required a single wire with the resistor in the tank as balance. Open circuit and the gauge pegs and might burn out from excessive voltage.
Another circuit will balance only one coil in the gauge.
I would say you have cut off a wire, or broken a plug @ the firewall. Probably putting too much weight on it while working on the engine.
When you find the problem you will probably need to replace the dash gauge too.
Best I can do from here.

Answer 2

Odd situation! Make sure the sender lines are not damaged or shorted to power. They might run through the main harness that you had to move to replace the intake.

Answer 3

I looked up the '98 Malibu fuel level sensor in the RockAuto.com parts catalog and this was the description:

ACDELCO Part # SK1189 {#19121302}
SENSOR KIT,FUEL LVL 2ND DESIGN; INCLS FUEL MODULE, RUBBER PADS, CODE JDC-FOR 1ST DES SEE 25314238

$81.89 $0.00 $81.89
ACDELCO Part # SK1050 {#25314238}
SENSOR KIT,FUEL LVL 1ST DESIGN; INCLS FUEL MODULE, EXC RUBBER PADS CODE JDB-FOR 2ND DES SEE 25317986

The mid-year redesign adding "rubber pads" might indicate the first design had ground problems as indicated by the earlier answerers.

Answer 4

If she refuses to pay for artwork already performed, you have the mind-blowing to hold the motor vehicle and placed a mechanic's lien on it for what you're owed. end of debate for that area. "in case you apart from would want us to restoration the gasoline gage project, which would be greater. do you want to authorize those maintenance, or not?" No pay, no vehicle. common eh? If she threatens to sue, tell her pass forward, yet she nonetheless desires to pay the invoice if she needs her vehicle back. If issues get gruesome, call the police and characteristic her got rid of.

Answer 5

i have a repair shop and it sounds like a ground problem . i have never seen this before. i have seen fuel gauge problems with this make but it is the sending unit