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milflyer Samba Member

Joined: July 22, 2025 Posts: 49 Location: Suffolk | England | United Kingdom
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Posted: Fri Oct 03, 2025 11:37 am Post subject: Fuel Gauge/ Fuel voltage regulator / Fuel tank sender ?? |
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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 Samba Member

Joined: October 02, 2006 Posts: 33510 Location: Hot Arizona
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Posted: Fri Oct 03, 2025 12:01 pm Post subject: Re: Fuel Gauge/ Fuel voltage regulator / Fuel tank sender ?? |
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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. _________________ 1970 VW (owned since 1972) and 1971 VW Convertible (owned since 1976), second owner of each. The '71 now has the 1835 engine, swapped from the '70. Second owner of each. 1988 Mazda B2200 truck, 1998 Frontier, 2014 Yukon, 2004 Frontier King Cab. All manual transmission except for the Yukon. http://www.thesamba.com/vw/forum/album_page.php?pic_id=335294 http://www.thesamba.com/vw/forum/album_page.php?pic_id=335297 |
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milflyer Samba Member

Joined: July 22, 2025 Posts: 49 Location: Suffolk | England | United Kingdom
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Posted: Fri Oct 03, 2025 12:06 pm Post subject: Re: Fuel Gauge/ Fuel voltage regulator / Fuel tank sender ?? |
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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 Samba Member

Joined: October 14, 2016 Posts: 2203 Location: Wichita, KS
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Posted: Fri Oct 03, 2025 12:36 pm Post subject: Re: Fuel Gauge/ Fuel voltage regulator / Fuel tank sender ?? |
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| 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. _________________ 1971 Standard Beetle — fairly stock / driver
baldessariclan -- often in error, never in doubt... |
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milflyer Samba Member

Joined: July 22, 2025 Posts: 49 Location: Suffolk | England | United Kingdom
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Posted: Fri Oct 03, 2025 1:26 pm Post subject: Re: Fuel Gauge/ Fuel voltage regulator / Fuel tank sender ?? |
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Great response folk ... really appreciate the replies
Should there be anything else to check?
Thank you |
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milflyer Samba Member

Joined: July 22, 2025 Posts: 49 Location: Suffolk | England | United Kingdom
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Posted: Sat Oct 04, 2025 4:03 am Post subject: Re: Fuel Gauge/ Fuel voltage regulator / Fuel tank sender ?? |
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| 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
Now the gauge and voltage regulator/vibrator to be checked  _________________ Bug#1 "1200CC - BBN446L" / Bug#2 "1302S HUE472L" / Bug#3 "Karmann Cabroilet NFC798S" |
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heimlich  VWNOS.com

Joined: November 20, 2016 Posts: 7578 Location: Houston, Texas
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Posted: Sat Oct 11, 2025 7:36 am Post subject: Re: Fuel Gauge/ Fuel voltage regulator / Fuel tank sender ?? |
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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. _________________ www.vwnos.com [email protected]
Classic Brands. Classic Quality.
Not all parts are made the same. NOS OE/OEM parts made mainly in West Germany, Early Germany, and Early Brazil are where VW produced the best quality parts and best fitting products.
5% Off your order with coupon code: 5%OFF
Restored Distributors Available (<--Click here) |
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milflyer Samba Member

Joined: July 22, 2025 Posts: 49 Location: Suffolk | England | United Kingdom
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Posted: Tue Oct 14, 2025 6:18 pm Post subject: Re: Fuel Gauge/ Fuel voltage regulator / Fuel tank sender ?? |
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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 _________________ Bug#1 "1200CC - BBN446L" / Bug#2 "1302S HUE472L" / Bug#3 "Karmann Cabroilet NFC798S" |
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