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E36 Fuel Gauge Sensors

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My fuel gauge starts off showing the correct level, then will suddenly jump to empty and occasionally then to full. It also returns to the correct level for a bit, before showing empty again.

I thought it would be the usual suspect - drivers side fuel sensor - but I've taken that out, looked for broken and cracked wires, checked the resistor surface, run the float over it's operating range and checked the resistance -all OK. Then I did the same checks on the passenger side - also OK.

The next step was to replace the instrument cluster (I needed one anyway) and the problem is still there.

Any ideas?

Jo

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How full & how empty does it show? To extremes? If so- would mean completely open circuit & short circuit. Have you traced the wiring? Hard to imagine a wiring issue causing extremes though

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How full & how empty does it show? To extremes? If so- would mean completely open circuit & short circuit. Have you traced the wiring? Hard to imagine a wiring issue causing extremes though

Very nearly full, and off the scale empty.

I get that empty = short circuit, but I'm mystified by the reading that's fuller than the tank really is - which indicates more resistance.

Btw, the drivers side sender (the expensive one with the fuel pump) is only 6 years old.

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Very nearly full, and off the scale empty.

I get that empty = short circuit, but I'm mystified by the reading that's fuller than the tank really is - which indicates more resistance.

Other way around - over full is a short circuit. empty is open

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Edit, you are correct for some older vehicle fuel gauge systems

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