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Fuel Gauge/ Fuel voltage regulator / Fuel tank sender ??
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milflyer
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PostPosted: Fri Oct 03, 2025 11:37 am    Post subject: Fuel Gauge/ Fuel voltage regulator / Fuel tank sender ?? Reply with quote

Evening all

Since buying my US import VW Karmann Cabriolet the fuel gauge has only ever indicated a 1/4 tank of fuel even though the tank was full.

A local garage said it would be the tank sender ... so I've changed it but nothing has changed!

Left in the system is the actual fuel gauge or it's voltage regulator.

Is there a test for the gauge/voltage regulator and or a fault test for the new tank sender in case its faulty.

Many thanks

John

PS: The tank sender I fitted as specifically for the 1302/1303
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Cusser
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PostPosted: Fri Oct 03, 2025 12:01 pm    Post subject: Re: Fuel Gauge/ Fuel voltage regulator / Fuel tank sender ?? Reply with quote

Remove the sending unit, and measure ohms resistance when the floats are all the way down, and when the floats are all the way up. Compare to specifications. Resistance of a sender for full tank should be 10-12 ohms and around 70 for empty.

And there should be gradual change in ohms as the floats are moved through the "throw", and no "opens" of zero resistance.
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milflyer
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PostPosted: Fri Oct 03, 2025 12:06 pm    Post subject: Re: Fuel Gauge/ Fuel voltage regulator / Fuel tank sender ?? Reply with quote

Thanks Cusser ... that's a start ...

I think I also read somewhere there is a test for the Speedometer end too?
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baldessariclan
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PostPosted: Fri Oct 03, 2025 12:36 pm    Post subject: Re: Fuel Gauge/ Fuel voltage regulator / Fuel tank sender ?? Reply with quote

milflyer wrote:
I think I also read somewhere there is a test for the Speedometer end too?

As a quick test of the fuel gauge and vibrator units, with the ignition switched on, remove and briefly ground the wire which normally attaches to the gas tank sending unit. The fuel gauge should read at or near full in this condition. If it doesn't, then you've likely got issues with the fuel gauge and/or vibrator.

Note that many (if not all) aftermarket units for these components (i.e. fuel gauge, voltage regulator "vibrator", and fuel tank sending units) are well known for often being incorrectly calibrated and/or completely out of spec, and are thus a common source of erroneous fuel gauge readings.
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milflyer
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PostPosted: Fri Oct 03, 2025 1:26 pm    Post subject: Re: Fuel Gauge/ Fuel voltage regulator / Fuel tank sender ?? Reply with quote

Great response folk ... really appreciate the replies

Should there be anything else to check?

Thank you
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milflyer
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PostPosted: Sat Oct 04, 2025 4:03 am    Post subject: Re: Fuel Gauge/ Fuel voltage regulator / Fuel tank sender ?? Reply with quote

Cusser wrote:
Remove the sending unit, and measure ohms resistance when the floats are all the way down, and when the floats are all the way up. Compare to specifications. Resistance of a sender for full tank should be 10-12 ohms and around 70 for empty.

And there should be gradual change in ohms as the floats are moved through the "throw", and no "opens" of zero resistance.


Thanks again Ian, this morning's test showed 9.3 Ohms at FULL and 79.3 Ohms at EMPTY with smooth increase across the range when the float was moved so I guess there's no fault there Very Happy

Now the gauge and voltage regulator/vibrator to be checked Rolling Eyes
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heimlich Premium Member
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PostPosted: Sat Oct 11, 2025 7:36 am    Post subject: Re: Fuel Gauge/ Fuel voltage regulator / Fuel tank sender ?? Reply with quote

If you are using an aftermarket gauge and/or sending I have a device I am testing showing very good results. It should be in production very soon. It attached to the back of the speedometer just as you would the vibrator. It fixes the issue with the aftermarket sender and gauge not reading correctly.
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milflyer
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PostPosted: Tue Oct 14, 2025 6:18 pm    Post subject: Re: Fuel Gauge/ Fuel voltage regulator / Fuel tank sender ?? Reply with quote

Good evening Heimlich

Thank you very much for your message!

I'm very interested in what you have to offer, more details would be most welcome.

Please keep me updated

Thank you

Kind regards

John
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Bug#1 "1200CC - BBN446L" / Bug#2 "1302S HUE472L" / Bug#3 "Karmann Cabroilet NFC798S"
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