It will read empty and will only fill to 12 gallons
The float on the fuel pump assembly has become saturated with moisture and it’s reading low. You need to replace the mechanism. It should be under The backseat.
If it were me, I'd pull the entire sending unit all in one piece from the junkyard and install it. Bet that would solve your problem. Sounds like something in the sending unit is bad or bent or something or not in tank properly which replacing the whole unit will solve.
SOURCE: Gas Gauge not reading correctly
The most likely culprit is the sending unit in the tank. They are relatively easy to change, as long as you don't have much fuel in the tank. It's a mechanical unit that has a float that raises and lowers with the fuel level, however with age, the floats can develop leaks and no longer float, of the electronic portion of the unit can go bad and not register the proper level. They are replaced and an entire unit, so it doesn't matter which happened, you will need to change the fuel tank sending unit.
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: 2006 GMC Envoy XL gas gauge reads empty
The sulfur content in the fuel is contaminating the contacts of the sending unit.
Some people have had good luck with some fuel system cleaners solving this problem. The cheap stuff doesn't seem to do the job.
Not that GM isn't completely exonerated from fault but the gas stations don't do a very good job of watching what the stations sell.
SOURCE: 2006 GMC Envoy XL gas gauge reads empty after
It is most likely your fuel level sending unit has gone bad. It sits inside your fuel tank to tell the fuel guage how much gas you have in the tank.
The sending unit for the gas gauge is in the fuel tank and part of the fuel pump module, it is not sold seperately. Price is around $350.00, 2 hours labor to install the part.
SOURCE: Why is gas gauge not working correctly since fuelpump was replaced.
Is this a flex fuel vehicle. If so, call the dealership and ask the parts dept. if there is a gauge module (perhaps behind the instrument cluster). This may be the culprit and needs to be replaced.
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