Fuel gauge issues are fairly common. W202 and W163 are the most common with corrosion on the senders. new senders are gold coated to help prevent the corrosion.

Instrument clusters usually get their coding changed to direct readin from the sender instead or a averaged out reading.

The only instrument clusters I've ever had to change for fuel gauge faults is in the 170 due to the guage reading too high (going about 45degrees past the full mark)

Unless your dealer can show you the bullten or service info on replacing the instrument cluster then I think they're having you on. I haven't heard about ording a instrument cluster with a preset milage either........It's programmed in after the new cluster is installed.

As a side note, I bought a 1998 w202 C240 yesterday........first thing I did was go and fill the tank, sure enough the gauge sat on empty after refuling . Doesn't bother me though, I've got 2 yrs warranty and I'll make sure I fix everything that's covered. It's nice knowing that I'll get paid to work on my own car for a change

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Alex.

MB Tech
Sydney, Australia
Volvo 122S
W201 190D 2.5 manual
W202 C240
W203 C32