All the electric gauges use a float of some sort which operates
a variable resistance, or rheostat.
One of the problems in measuring fuel level is the fact that
fuel sloshing about will bob the float up and down, giving
erratic readings. Two schemes are used in VW gauges to overcome
this.
In one, the float is encased in a vertical cylinder with only
tiny holes allowing fuel to pass into the cylinder. Thus, even
if the fuel level outside the cylinder varies rapidly, the level
inside remains relatively static.
The gauge is a simple voltmeter style and responds rapidly to
changes in float resistance.
In the second scheme, the float is allowed to bob up and down at
will but the signal is damped by the gauge mechanism. In this
case, the float resistance is used to heat up a bi-metal arm
inside the gauge. As the float moves toward Full, more current
flows and the bi-metal gets hotter, thus raising the needle's
position.
To improve the accuracy of the bi-metal type gauge, a form of
voltage regulator is used to supply current to the gauge. The
most common type used was a mechanical vibrating contact which
alternately turned current on and off going to the gauge. A
bi-metal inside the regulator made it responsive to the incoming
voltage. This regulator (or stabilizer, or simply vibrator)
was mounted on the back of the gauge.
How To Test: In case of mal-function it's important to be
able to tell ff the problem lies in the tank sending unit or in
the gauge.
1) Disconnect the sending unit wire. The gauge should move to
Empty.
2) Short the sending unit wire to ground. The gauge should move
to Full.
If it passes both tests, the gauge itself is working
correctly.
If it does not pass, the sending unit may be defective.
Other possibilities: If the gauge does not move at all, the
fuse supplying the circuit may be blown, or the vibrator may be
defective.
If calibration is off, the vibrator could be defective or the
sending unit is sticking or defective.
Erratic gauge readings can be caused by a worn out sending unit
or, possibly, by loose terminals on the gauge. Loose terminals
were quite common on some model years.
If you have to remove a sending unit, use extra caution. Some
units twist into the tank with a bayonet-style lock. Use tools
which won't create sparks when removing. In all cases, keep
any flame away and don't use a "trouble light" which could
ignite fuel. Disconnect the battery before doing any work on
the fuel tank.