What year gauge is in the car right now, a 64, zero to 31 Ohms (range span) or a 65 gauge (zero to 90) ohms range span? Did you test the sender before you put it in the tank? ALL senders should be tested prior to install, it is almost certain that the makers of new reproduction parts do not bother to test their senders prior to shipping.
Your test #1 does not seem right to me. Could you post photos of the front at the back of the gauge? Also that gauge needs ground at the silver steel plate which is the access hatch at the back of the gauge. Without a "reference ground" at the dash the gauge will never work!!!
I would like to see how this is wired. Any GM dash gauge for Fuel, temp or oil pressure absorbs voltage so the input voltage (measured) would be at least 11 volts; more in the range of 12 or 13 if the engine is running but the output voltage from the tan wire back to the sender would be no more 3 or 3.5 volts. Especially with a fuel gauge; you would NEVER EVER run 11 volts into a fuel tank sender. A) that could burn the resistor card & damage the sender and B) If that were to ever spark across the resistor card via the copper touch tab and there was almost no fuel in the tank the resulting spark could very well ignite the vapors inside of that tank, which would be VERY BAD !!!
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Peter Serio
Owner, Precision Pontiac
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