Unreliable Fuel Gauge on Fiat Ducato (1 Viewer)

May 22, 2016
77
22
Surrey
Funster No
43,223
MH
Adria Matrix 600DT
Exp
Since 2012
The fuel gauge on our Ducato based Hymer seems to be getting more and more unreliable by the month. Its reached a point where we now look at mileage driven rather than the fuel gauge, although this is now too stressful!!!
The tank-breather seems to be ok and Ive not got any (vacuum) distortion of the tank so can only put the issue down to faulty measurement.
Whats the mechanism for measuring how much fule is in the tank? Is it a mechanical float-type of thing or is it solid-state sensors?
Its quite an old van, 2002, so maybe something has just worn-out?

Any suggestions?
 
Jan 28, 2008
10,104
18,260
Dovercourt, Harwich, UK
Funster No
1,353
MH
Renalt burstner
Exp
7 years campers before that
that age i would imagine a float operated but thats not gospel is there a floor hatch to get to it under the seat?
 

pappajohn

LIFE MEMBER
Aug 26, 2007
43,207
48,811
Dark side of the moon
Funster No
172
Exp
Since 2005
Mine used to be all over the place...full then half then full then empty then half then empty and so on..2001 model
Have a look under the rubber floor cover on the left hand side in front of the seat
Under the cover is a steel plate held with a few screws....about 6" across
Under the plate is the fuel gauge connection plate and, from memory, the fuel feed and return pipes.
Pull off the connector block, clean the spade terminals with a bit of wire wool/emery tape, wipe with a little petroleum jelly/vaseline and refit.

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Nov 4, 2011
5,888
38,113
Uk
Funster No
18,763
MH
A class
Exp
2001
I suffered this problem for years, as you say always fill and zero trip.
Well the fix on mine was easy- thanks to somebody post on Facebook Hymer group- remove lower dash panel on passenger side-4 screws- and you will find a box about 2”long by 1”x1 1/2” near the relays, remove connector block and spray with WD40 and refit.
This sorted mine, still reset the trip just in case.
 
Feb 21, 2016
4,910
29,131
Uk
Funster No
41,726
MH
C class
Exp
Since 2017
On my 2006 2.8jtd,the first half of the tank goes down rapidly,but the second half lasts for ages.
And when it says I’m on reserve,I reckon there’s about 15 litres left!!
OK once you get used to it.:D
 

Lot lover

Free Member
May 13, 2016
1,291
1,617
Lot, France
Funster No
43,061
MH
Le Voyageur Integral
Exp
New boy
Who needs a fuel gauge? Once you have determined how far you can go on a tankful reset trip to zero on filling up, and refill at 75% of kilometres covered - or is that too simple?

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Jul 25, 2017
407
1,096
Rugby
Funster No
49,630
MH
Elddis Autoquest 185
Exp
Since2012
I had that issue as well, fill up next thing low fuel light on. The black box mentioned above has a circuit board inside. Common issues for dry joint had all joints resolderd and cured problem. Couldn't get enough heat with diy soldering iron so had a neighbour who is electrician sort it. Under magnifying glass he could see crack in soldered joint
 
Nov 4, 2011
5,888
38,113
Uk
Funster No
18,763
MH
A class
Exp
2001

Mines a 2001 Hymer B class LHD
Pass on what’s in the box, I didn’t open it.

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Aug 6, 2013
11,941
16,533
Kendal, Cumbria
Funster No
27,352
MH
Le-Voyageur RX958 Pl
Exp
since 1999
All vehicle fuel level sensors are float operated. Any electronics prior to the fuel gauge itself are likely there to operate the low fuel warning light or concerned with the in-tank pump.
 
Nov 1, 2021
13
22
Brecon Beacons, Brecon, UK
Funster No
85,207
MH
Mabinogion123
Hi
Thanks for the info. Have narrowed it down to connector/module under dash
Can you tell me how to revove the Module to clean the board?
thanks. Gareth

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NicM

Free Member
Oct 6, 2021
274
1,321
UK
Funster No
84,695
MH
Old Hymer
Exp
2020
The only way to test it all is to remove the sender from the tank and move it by hand and see if the fuel gauge moves from full to empty with no dead spots, you can also use a Multimeter to test just the sender unit.
 
Aug 6, 2013
11,941
16,533
Kendal, Cumbria
Funster No
27,352
MH
Le-Voyageur RX958 Pl
Exp
since 1999
Over the years there seem to have been numerous issues with the Ducato instrument cluster apparently down to poor connections or dry joints. Does your handbook not list the warning lights that should appear when the ignition is first turned on?
 
Jan 27, 2018
2,648
2,087
Northampton
Funster No
52,151
MH
Rapido & Bongone
Outside the box
if you have a useable OBD port you could use something like Torq to monitor fuel left (ecu value) or even distance remaining. i currently use mine to monitor speed temperature and trip fuel consumption.
 

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