Symptoms of Failure of Fuel Gauge Sending Unit and How to Replace it

About fuel gauge sending unit

The fuel level gauge of a car measures the fuel level inside the tank. The fuel level in tank is used to allow fuel to flow to the engine and allows excess fuel to return back to the tank. In some vehicles, the the fuel level sending unit is also included with fuel pump, which usually comes with a fuel sock.

The fuel sending units differs in terms of how they are designed, their functional purpose remain the same.

In the interior of vehicle, there is a fuel gauge that sets up driver with a visual indication of fuel left inside the fuel tank. It helps the driver monitor the fuel level in the vehicle and when the tank needs to be filled up, and avoids running out of fuel. The major component of fuel delivery system is the fuel sending unit. It measures and gives information on fuel level which gets displayed on the dashboard informing about the current level of fuel in the tank.

LocationThe fuel gauge sending unit is located in the fuel tank. The fuel tank sending unit consist of a float inside the fuel tank. The fuel sending unit consist of metal rod which is connected to a resistor. The resistor sends electrical signals to the fuel gauge on your dash board.

Symptoms of failure of fuel gauge sending unit

• Showing empty on fuel gauge even fuel present in the fuel tank
• A fuel gauge needle on the dashboard of your vehicle is resting on empty even though the vehicle has fuel in the fuel tank.
• It is one of the indications of failure the fuel gauge sending unit parts.
• It is also caused by defects in the wiring between the sending unit and gauge.
• Proper operation of such devices should be confirmed before replacing a sending unit.

• Non functional display of needle on fuel gauge
• When the fuel sending unit fails, the fuel gauge needle hangs in only one position and fails returning to normal operation.
• This is an indication that the float in the fuel tank sticks in one position due to mechanical deficiencies.
• The fuel sending unit experiencing this condition can break down when the float reaches the sticking point due to fuel level changes.

How to replace a fuel gauge sending unit

• First, park your vehicle in a safe area and switch off the ignition system.
• Disconnect the battery to prevent electrical issues during repairing.
• Remove the battery's negative terminal connection using wrench and disconnecting the cables.
• Disconnect the positive terminal connection cables.
• Empty the fuel tank before starting therepair work.
• Place a bucket or a fuel can under the drain.
• If there is no drain valve exists, locate the fuel lines and disconnect it from the fuel tank.
• After emptying the fuel tank, locate the fuel sending unit.
• Remove the fuel sending unit by disconnecting the connections and remove the remaining bolts.
• Now, install a new fuel gauge sending unit in place of the old one.
• Test the motion of the floater and wiper in the fuel sending unit to ensure all the parts move freely.
• Repeat all the steps that you have taken to remove the fuel sending unit and reconnect to fuel sending unit.
• Fill the fuel tank with the fuel drained earlier. After installing new fuel gauge sending unit, turn on the engine and test the working of fuel sending unit.

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