Chrysler Repair: Gas low chimes/gauge reading is flaky:97 van, ohm resistor, gauge function


Question
My 1997 Dodge Caravan has 3 things happen simultaneously :  (1) the gas gage drops to zero, (2) the low fuel indicator light illuminates, (3) the chime dings.  This happens every few seconds.  Ding, Ding, Ding.  This started about 2 weeks ago, and hasn't stopped.  I don't want to invest a lot in the van, and would be happy to simply disconnect the chime if possible.  

Answer
Hi Bob,
The chime I suspect is built-in to the body control module which is located on the back side of the junction block (fuse box) under the dash. If you can get it to chime while standing still to listen for the source of the sound try to locate it there, under the dash on the left side. I see no separate chime module listed in the wiring diagram and I know that in earlier models it was built-in to that computer. Because of that, one way to solve this is to muffle the speaker grille with some foam, or remove the body module and open it up and disconnect the wires to the chime. The signal from the variable float resistor in the fuel tank is probably gotten flakey due to wear and tear but you might want to verify that there is not a "open" in the float signal wire (dark blue) that runs from the tank to the body controller. I suspect that you can't turn off the chime sensor function independently of killing also the fuel gauge function, as the chime is probably triggered by some voltage reading coming from that variable resistor. If you wanted to give up the fuel gauge and thus get rid of the chime, then just go back to the tank, remove the plug and wire a 70 ohm resistor between pin 1 and 3 (or between the dark blue and the black wire) but in such a way as to allow the plug to be reinserted as the black wire is the ground wire for the sensor and the fuel pump. Then the gauge will read full all the time. It may be that there is a break in the wire that opens the sensor circuit which would cause the gauge to read empty. So you might try flexing the dark blue wire and the harness it goes into between the tank and the engine controller plug (pin 46) with the ignition "on" to see if you can make it chime. That way you could find the break and repair it, if that is the cause rather the float in the tank. The wire might just be loose in the plug, for example, or corroded.
Those are the possibilities as I see it.
Roland