I have purchased my Lexus NX300H from USA auction. Since I live in EU a car made a long trip and had many loadings-unloadings.
Recently I noticed that fuel level arrow on dashboard indicates wrong level of fuel. If it is on lowest division the fuel tank is acually empty. I was lucky because I noticed that being at home
One suspition I have is that during transportation from USA to EU tank was pressed or hit by loader and the fuel sensor lockaed inside of tank was somehow bended. But to check it the fuel tank must be removed and such procedure takes a lot of work.

Maybe somebody had similar issue and can offer a solution how to proceed now: to "repare" existing sensor or better to buy new one for replacement? And any ideas how to check described suspition without removing fuel tank?

 

Unfortunately, to access, test, or repair the fuel level sensor requires removal from the tank (and therefore removal of the fuel tank). Refer to the attached drawing. The fuel level sensor "float" is marked with a red ellipse. The approximate position of the sensor float is shown at upper right for Empty, 50%, and 100% fuel levels.

Since the float is free to move, I think the more likely cause of your problem is deflection of the tank bottom in the region marked with a red arrow. To minimize weight, the tank is fabricated from thin sheet metal and an adult could bend it without any tools. If the tank bottom has been deflected inward, the float cannot extend to the "E" position, which would result in the condition you described. This damage may be discernible by visual inspection.

The fuel pump motor depends on constant immersion in fuel for cooling. It is not a good practice to permit the fuel level to fall below ~25%, because effective cooling will be diminished at service life of the fuel pump will consequently be reduced. If you adopt a habit to refill the tank when the fuel gauge level reaches ~25% (or higher), you will maintain pump cooling and the accuracy of the "Empty" indication will not be important. This is the "no cost" solution I recommend .

 

Have you examine visually the general area where the float & sensor assembly is and is the tank bottom pushed up and deformed permanently ?
If the affected area of tank bottom is smooth ( as being devoid of manufacturing indentations to provide rigidity ), you can try using vacuum from a suction cup ( e.g. toilet bowl plunger ) to pull down deformed area ( this is a common practice of body repair shops here in NA. Good luck.

 

There are some reasonably-clear images of the top and bottom of the tank here:
https://www.ebay.com/itm/37559012217...rhlTMCrxdJXiNk

 

n0v8or, many thanks for detailed explanation and sketch. You are right, now this foult train me to keep 25% of fuel level in the tank and save fuel pump. But it gives effect only after repairing.

Lexura16, I did not check the bottom of the car till now but I will do this for sure. I know about suction method to correct surface. It is often used when you need to repair car body dents. But I have not heard about toilet bowl plunger to use for that. Good idea and good tool

Will keep you informed how it goes.

 

I can only imagine that it would be quite an ordeal to get into the tank and fix that.
If I were you, what I would do is simply ADJUST YOUR MIND to the new range on the gauge.
Here's what I suggest:
1. Start off with your best ESTIMATE on you mpg. (for purposes of this explanation, let's go with 25mpg)
2. NOTE what your tank capacity is (found in your owner's manual) (for now, let's go with 15).
3. Fill the tank. With nozzle in tank, STOP filling when the clicker on the nozzle clicks to STOP. DO NOT put any more into the tank.
4. Watch your ODOMETER. Wait until you're as close to 350 miles driven since the fill-up ( (25mpg * 15 gallons) = 375 miles - 25 miles fudge).
5. Perform another tank fill-up (as above).
6. Take note of WHERE the gauge is pointing. That is your new (almost) empty point.

Personally, I would never bother to pull the tank for something like this. As long as the gauge is in 'working' order, I wouldn't be so concerned that it is off in the way you described.

 

I noticed this problem when engine refused to start so tank was empty. Fuel arrow pointed exactly at 25%.
I do not see a problem to train my mind but even if I do that and later give a car to my wife or sun what will happen then I do not know

 

If it's a one-time use/loan to someone, and you concluded that the 1/4 mark is "empty" (or close to it), then you simply tell them "DO NOT let the fuel level get below the halfway point".

Otherwise, if you're permanently transferring ownership, then you have to give the recipient the FULL STORY.