Hi, I recently had a problem where the fuel gauge showed empty even though the tank was half full.  This I sorted out by removing the pump and level float sensor from the tank and fitting a new float level sensor.  The sensor I bought from AutoDoc for about £12 plus about £10 postage.  It came from somewhere in the EU and I was inmpressed with the service from AutoDoc.  The part arrived within a week and was very well packed for what is quite a delicate part.  The part was fairly easy to fit.  The only tricky bit was disconnecting the electrical connectors from the sensor and from the new part (it came with connectors and wires attached).  Once the connectors were disconnected the existing wires/connectors were made up to the new sensor.  There are several YouTube videos which show how to remove the pump and sensor unit from the car.

I trust this helps someone.

Hi, Unfortunately it is not fixed.  I think there is a wiring issue.  When I fitted the new sensor it seemed to work OK for short while and then again was erratic.  I fitted a replacement pump and sender unit and have the same problem so thats why I think there is a wiring issue.

Highly likely to be a cracked solder joint where the green connector is soldered to the instrument cluster circuitboard.

Hi Breezy_Pete,

Many thanks for replying.  I have done some more searching and your suggestion re dry soldered joints looks very likely.

I found the following video which covers cluster removal and repair.  My son is a dab hand at soldering so hopefully he can help me out.

So again, many thanks.

 

No worries.

I think one of the other threads you posted in may have indicated the specific location of the relevant pin. If not, I can re-find that info for you.

I believe it will be possible to get enough access without removing the dial needles and flexible bezel, instead just lifting/bending this bezel out of the way. 

 

 

The fuel gauge pin is apparently No. 15 and in this video the guy just lifted/bent the bezel out of the way.  Surprisingly getting to the internals of the cluster looks quite easy compared with most dashboard related jobs.

Hi, I got the cluster out and all the solder joints looked OK.  But I got my son to resolder No.15 pin but unfortunately this made no difference.  I remember reading that this problem can be caused by a bad earth to the  fuel level sensor.  And the fix I believe is to link the sensor earth to the earth of the fuel pump.  I will investigate this.

The image below shows the pins after pin 15 has been re-soldered.

The brown/white earth from the gauge should end up on pin 32 of that same connector, check if it does (and that pin connection, can't see well cos of the green peg.

 

 

HI, We had a good look at all of the pins and they did look OK including pin 32.

I'm remembering vaguely that the fuel gauge and outside temperature sensor behind the front bumper share a voltage source. Anything odd going on with outside temperature readings?

I drew out the circuit within the cluster board somewhere, might be able to find again.

 

The outside temperature gauge has been reading OK.