You likely need to replace the float/level sending unit. Depending on the vehicle, you may have to remove the gas tank. Had to replace the on in my wife's Pathfinder a few years ago and had to drop the tank to get to it. My Accords unit can be accessed through a small hatch by pulling up the back seat.
You will need to remove the fuel pump from the tank and replace the calibration dial on the side of the bracket for the pump. I am brain dead now as it is 3:00am almost and I am not able to remember what the name of the calibration unit is ,but it will need to be replaced. hope this helps.
SOURCE: Fuel gauge registers empty after fill up
It sounds to me like you have a short in your wiring harness at you fuel tank. there is a plug on top of your fuel tank that controls you fuel pump and your sending unit that tells you how much fuel is in the tank. This plug can be a real p.i.a to get to on some vehicles, you may have to take the vehicle to a shop to fix it, if you are not mechanically inclined.
SOURCE: gas gauge reads empty but tank acts like it's full
I also have a 04 with a 1.8L. same problem. I took the fuel regulator off. It is a black box behind the rear tire under car. It only has 2 bolts to take off. After that there is a couple of vent hoses from the tank going to this box. Unplug them and 1 electrical connection. The electrical connection and one vent is connected to a T connection on the box that you can unplug by twisting on the T. Take that T off and look inside where you unplugged the hose on this T. There is a spring and a little plunger inside this tube. The plunger gets stuck. I took a little screw driver and some PB blaster and worked that plunger back and forth a couple dozen times and it unfroze. Put it back together gassed up just fine. I did not look but I was told regulator can be replaced for 200$. But a can of blaster is cheaper.
SOURCE: 2001 hyundai sonata 4 cl can't pump fuel into tank @ normal rate
The sending unit in your tank is going bad replace it.
SOURCE: When the gas tank is full the gas gauge shows as
Well that tells me that someone installed the wrong fuel level sensor. Your going to have to drop the tank and pull the pump and float assymbly out. Then go to a parts store and get a sending unit that has the opposite resistance of that sending unit. Just wait until the tank is empty so its a lot lighter. You can call the parts store or go down and see if there is multiple sending units. The sending units work by resistance, when the tank is full the float moves up and turns a wheel in the sending unit, which either removes or increases the resistance causing the gauge to lower. The sending units either give full resistance at full or no resistance at full and then changes as the level goes down until it does the opposite at empty.
SOURCE: gas gauge stuck on empty
Mine did the same thing. If you've tried starting it with a flat battery, the needle twitches and comes back up on the underside of the gauge rest pin. You have to remove the instrument cluster and slowly rotate it so the needle goes back to the top side. Its happened to me three times now.
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