How to repair gas gauge of the car?

Many of the gas (fuel) gauges do not work for simple reasons. It would strongly suggest you read this document before proceeding. You may want to repair this problem in a different way. Just note. Your cars are usually molested pretty well by the time you get them. Make sure your wiring under the dash is in good shape. If it is not then I would suggest you start there. It may be the problem. Remember your body should be proper ground, and the wires carry the voltage. And there are also few ground wires under the dash. So be always careful when you splice something.

Repairing Gas Gauge
Repairing Gas Gauge

Gauge consists of two parts:

  1. Sensing unit
  2. Indicator
Sensing unit uses a float connected to a potentiometer. As the tank empties, the gas passes and slides a moving contact along the resistor, increasing its resistance. It will also turn on a "low fuel" light on some vehicles

Indicator unit (mounted dash board) is measuring and displaying the amount of electrical current flowing through the sending unit. When the level of the tank is high and maximum current is flowing, the needle points to "F", full tank. When the tank is empty and the least current is flowing, the needle points to "E", empty tank. This is same as shown in figure, contain all the vehicle.

Most common problems occurs:

  1. Defective gash gauge
  2. Lost of a ground at the sending unit
  3. Breaking cut on wire going to the dash

What should do while repairing?

First, check the fuse for the instruments. That fuse feeds the voltage limiter. When, voltage limiters tend to go bad, it burned out, it may have blown the fuse. But, if the fuse is good and the temperature and fuel do not work, then chances are one of two things - lost of ground or the limiter is bad.

After you are sure the fuse is good, (check with ON), you can go for the checking for a ground to the cluster. If your cluster is back lit, and the dash lights work, chances are you have a good ground to the dash. If it is front lit like the Mopars of the early 70’s, then we need to check the ground. If you have any lights on the dash, oil light (idiot light) turn signal indicator and they work, then a ground is established.

If all these things are good, then you have to go for the voltage limiter. This is where the fun starts. If you cannot, then you will need to remove the cluster. I strongly advise you disconnect the battery while removing the cluster. Once out, you can reconnect to finish your test. These we must take in mind while checking the fault.

In most of the cases, fuel gauge problems originate inside the fuel or the gas tank, where the mechanical/electrical fuel level potentiometer is. You need to drop the fuel tank out of the vehicle, and replace the fuel sender assembly or check the gas is not leak. Locate the gas tank and see if you see some wires hanging down. This is the gas gauge. You may have to put a connector on.

The first thing you can do is try to fix it. Take a look at your gas tank. It is probably in the back of the car, under the trunk, but if you have an old car that is a rear engine then it is probably in the front of the vehicle. Now that you have located your gas tank, look for an odd thing that has wires coming off of it.

Take a look if there is no wire, but there is a spot for a wire to go. Most likely that is the problem. You find one, you might need to repair it by connecting it to another piece of wire and putting a connector that will fit on the gas censer.

The connection is wiggly take it off and close up the female and pinch the connector so that it is a bit smaller. After that, force the connection back together. It should fit snugly so that you can not wiggle the wires much more. Good connection should allow the electricity to flow more freely and the censor should be fixed.

Try to solve gas gauge, it is not too difficult, if you are aware of problem like these. Hope these will helpful to all you people.

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