Faulty Fuel Gauge That Seems Impossible To Fix!

[darton]

Hi all, The fuel gauge in my 2001 Ford Galaxy 1.9TDi PS90 has never worked properly since I bought the car a couple of years ago. It generally reads full as soon as you turn the key what ever the amount of fuel, it will eventually drop to the correct reading after around 300 miles (but not always), sometimes it even reads correct when you turn the key,so long as there is no more than half a tank full.I have replaced the fuel tank sender unit for another but to no avail,it immediately read the same way as when the the old one was fitted.I could change the cluster but I have heard that may not stop the problem either, due to a known compatibility problem. the rest of the cluster works perfectly,its just this darn gauge!I have no choice but to fill the car every time so that I can reset the trip count to zero so as to know roughly how far I can get!

If any one has any fixes or info it would be very welcome :angry2: Cheers chaps

[Paul]

Hi all, The fuel gauge in my 2001 Ford Galaxy 1.9TDi PS90 has never worked properly since I bought the car a couple of years ago. It generally reads full as soon as you turn the key what ever the amount of fuel, it will eventually drop to the correct reading after around 300 miles (but not always), sometimes it even reads correct when you turn the key,so long as there is no more than half a tank full.I have replaced the fuel tank sender unit for another but to no avail,it immediately read the same way as when the the old one was fitted.I could change the cluster but I have heard that may not stop the problem either, due to a known compatibility problem. the rest of the cluster works perfectly,its just this darn gauge!I have no choice but to fill the car every time so that I can reset the trip count to zero so as to know roughly how far I can get!

If any one has any fixes or info it would be very welcome :angry2: Cheers chaps

 

Hi Darton,

 

Cant offer a fix but can offer membership to the same club! I have 52 1.9Tdi 115 and the gauge behaves in a similar fashion (since the warranty expired!). Sometimes it fails to register at all at switch-on. I find I can clear this occasionally by switching ingnition off and on again. I had the cluster checked by someone who has VAG.com, you can test all of the gauges with this ie Speed, Rev, Temp and Fuel. Mine checked out OK.

[cyborg]

Hi all, The fuel gauge in my 2001 Ford Galaxy 1.9TDi PS90 has never worked properly since I bought the car a couple of years ago. It generally reads full as soon as you turn the key what ever the amount of fuel, it will eventually drop to the correct reading after around 300 miles (but not always), sometimes it even reads correct when you turn the key,so long as there is no more than half a tank full.I have replaced the fuel tank sender unit for another but to no avail,it immediately read the same way as when the the old one was fitted.I could change the cluster but I have heard that may not stop the problem either, due to a known compatibility problem. the rest of the cluster works perfectly,its just this darn gauge!I have no choice but to fill the car every time so that I can reset the trip count to zero so as to know roughly how far I can get!

If any one has any fixes or info it would be very welcome :angry2: Cheers chaps

 

Hi Darton,

 

Cant offer a fix but can offer membership to the same club! I have 52 1.9Tdi 115 and the gauge behaves in a similar fashion (since the warranty expired!). Sometimes it fails to register at all at switch-on. I find I can clear this occasionally by switching ingnition off and on again. I had the cluster checked by someone who has VAG.com, you can test all of the gauges with this ie Speed, Rev, Temp and Fuel. Mine checked out OK.

 

 

Hi same thing happened to me with a temp gauge so i disconnected the speedo clock's 5 screws iirc and unpluged and plugged in again the fault disappeared.

[Mirez]

Seem this a quite a few times before on various VW's and its normally the cluster as fault - the guage sweep isn't a real indication thats its working, the controllers for the guages are addressed by a master controller which is bypassed in the sweep test - its also just told to go to max, min and half digitally and not via an actual signal.

[darton]

Seem this a quite a few times before on various VW's and its normally the cluster as fault - the guage sweep isn't a real indication thats its working, the controllers for the guages are addressed by a master controller which is bypassed in the sweep test - its also just told to go to max, min and half digitally and not via an actual signal.

 

so its a sort of "gauge by wire" sooner than a direct electrical link to the sender unit?

In which case Cyborgs answer may stand a good chance of working!? (Iam a bit of a novice at the electricals so I am totally reliant on all your info!)

Edited October 8, 2010 by darton

[darton]

Seem this a quite a few times before on various VW's and its normally the cluster as fault - the guage sweep isn't a real indication thats its working, the controllers for the guages are addressed by a master controller which is bypassed in the sweep test - its also just told to go to max, min and half digitally and not via an actual signal.

 

so its a sort of "gauge by wire" sooner than a direct electrical link to the sender unit?

In which case Cyborgs answer may stand a good chance of working!? (Iam a bit of a novice at the electricals so I am totally reliant on all your info!)

Oh and another thing,Paul,was your problem solved when the cluster was plugged back in? thanks.

[Mirez]

<BR>so its a sort of "gauge by wire" sooner than a direct electrical link to the sender unit?<BR>In which case Cyborgs answer may stand a good chance of working!? (Iam a bit of a novice at the electricals so I am totally reliant on all your info!)<BR>

<BR><BR>Correct on both counts, corrupt data will be erased with a cluster "reboot" - normally its a little more then that though but you''ve nothing to loose by trying it.<BR>

[darton]

<BR>so its a sort of "gauge by wire" sooner than a direct electrical link to the sender unit?<BR>In which case Cyborgs answer may stand a good chance of working!? (Iam a bit of a novice at the electricals so I am totally reliant on all your info!)<BR>

<BR><BR>Correct on both counts, corrupt data will be erased with a cluster "reboot" - normally its a little more then that though but you''ve nothing to loose by trying it.<BR>

 

Thanks Mirez and all, I'll give it a go and let you know results,...Cheers chaps

[darton]

And the result is...no change! so what would be the next step guys? :D Edited October 10, 2010 by darton

[Mirez]

Replace the cluster, or borrow a known good one to test.<BR>

[darton]

Replace the cluster, or borrow a known good one to test.<BR>

 

Thanks Mirez, I'll get onto it and see what I can come up with,many regards for the help :D

[darton]

I've replaced the cluster for a different one, and it does exactly the same thing,straight up to full,everything else on the new cluster also works perfectly, so I'm guessing either a wiring fault or this incompatibility issue that I have heard of between the the sender unit and the cluster!..anyone got any ideas of what I should do next? can the cluster be re-programmed or checked somehow?..Neil Edited October 17, 2010 by darton

[cyborg]

Just a thought!might miles out, but check for blown tail bulbs or might be bad earth connection on osr rear light.Also check any earth points .

[darton]

Checked all that in general and cannot seem to find a problem with the bulbs or earths!

 

Can any one tell me if a cluster from a 2.3 petrol Galaxy would be compatible to fit my 1.9 TDi (same years 2000-2002) the code on the new one is YM21 10849 AJC on the existing one its YM21 10849 ARD...Thanks

[chrispb123456]

Checked all that in general and cannot seem to find a problem with the bulbs or earths!

 

Can any one tell me if a cluster from a 2.3 petrol Galaxy would be compatible to fit my 1.9 TDi (same years 2000-2002) the code on the new one is YM21 10849 AJC on the existing one its YM21 10849 ARD...Thanks

Hi there

When you changed the tank sender did you test for earth at the plug? you may have an intermittant earth.

 

As you now have a spare tank unit you could plug that one in and move the float watching for any reaction on the gauge.

[darton]

I'm afraid I chucked the old one away! whoops, but I will go over the earths again and at the plug as you mention, might even try bypassing the loom just in case a wire has been rubbed somewhere under the carpet! Edited October 20, 2010 by darton

[boss1978]

Hi, New to this site as just bought the obvious. I have heard that the fuel gauge dancing can be due to low power in the battery? I had my battery checked as have the dancing gauge problem and my battery does need replacing. I charged the battery up over night and it seemed to fix the gauge but only for a few days.

Buying a new battery anyway as starter motor is struggling so will post if any joy.