I have a fluctuating / flickering fuel gauge in my car when I got to 3/4 tank and below. Short video of that is here:
If was able to fix this problem by removing and cleaning the fuel tank sender.
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Sender part number: 124 542 03 04 (did NOT need to buy, only remove and clean, its over $100 now)
Parts Required for this HOW-TO (the o-rings for the sender large holder nut)Large O-ring: 010-997-81-48
Small O-ring: 010-997-80-48
Special Tools Required:
- 46mm socket. I bought one called a BikeMaster Fork Cap Nut Socket (46mm) from Amazon for $24 It can be used with a 1/2" drive ratchet (many others required 3/4" driver ratchet, I don't have one of those)
I created this HOW-To by first referencing this excellent DIY at this link and creating my own photos of the procedure below specific to the E500E: http://www.peachparts.com/shopforum/...g-testing.html
Drive car until fuel tank is below 1/4 full. I was about 1/8 full. Do NOT do this with a full tank!
0) Open trunk and disconnect battery.
1) The fuel sender can be easily accessed from the trunk of you car.
2) Remover the back wall trunk liner from your car and there are two of those black interior trim clips that need to be removed. Use your interior pry tools to remove the center plunger and remove the clip.
3) The sender is now visible in the top center of the tank.
4) The connector can be removed by pulling it off. No secret trick.
5) Used your 46mm socket to loosen the larger sender holder nut. Then remove nut by hand.
6) The fuel level sender then easily lifts up and out of the tank.
7. You may have to clean the bottom black cap with brake parts cleaner to reveal the tiny nut underneath. Mine was gummed up with black gunk.
8) Now you need a slotted flat blade screw driver to underscrew large sender tube bottom plate. Lucky for me I have a wonderful Boxer "Security Bit' driver set that comes in handy for all kinds of odd jobs. A tiny pair of needle nose pliers may also work.