Installing fuel sendig unit

VIP Sponsors. Installing A Fuel Gauge and Sender. Fuel gauges seem like a simple device that we would assume to be standard across most all vehicle lines. Actually they vary widely from one make of vehicle to the other. This table of offerings from a fuel gauge sender supplier illustrates how they differ from one make to the next. Therefore it is important to use the gauge and matching sender in your project. Only one hole for the sender is supplied in an original tank, unlike the fine reproduction tanks that come with two.

The second hole in them is for the fuel pickup or electric pump in fuel-injected cars. I had to rotate the flange slightly to allow for drilling holes to match the six-hole pattern on my tank. A new gasket was made and the unit cut-down to account for the depth of the tank.

Most sending units have a float assembly that has to be modified to fit the depth of the vehicles tank. There is a new alternative now available that you might consider if you are still in the process of selecting a gauge set. It is a new type of floatless fuel sender from Classic Instruments. Sender must be mounted perpendicular not at an angle from the top of the tank. You simply cut it to length and calibrate it for your application. Just make sure that it is compatible with your gauge.

New floatless fuel sender from Classic Instruments. The following photo sequence shows the steps necessary for the installation of my fuel sender and routing of fuel lines on my roadster. The lead hole is degrees from opposite side of the sender wire egress. Position the new level sending unit above the tank, aligning the screw hole pattern in the mounting plate with the hole pattern at the top of the tank. Align the sender lead hole with the tank lead hole marked previously.

Install the level send ing unit with the aligned gasket by inserting the down tube into the tank. Make sure to e mpty the tanks of fuel and fumes before installation. Secure the level sending unit to the tank by tightening the mounting screws into place using a star shaped pattern. Do not over-tighten, this weakens the seal. E xcessive torque or re-tightening can cause the gasket underneath the sender head to be over-compressed or pinched in at least one area, d ramatically reducing the service life of the gasket.

This could result in failure leakage , while in service. To ensure the level sending unit is proper ly install ed , a leak test need s to be conducted. Pressurize the tank to 3 PSI and look for bubbles using soapy water around the seal see Figure 3 below. If bubbles are present this means that the SAE 5-hole mount screws ar e n ot tight enough. P roceed to tighten these screws in a star shaped pattern and r erun the leak test until bubbles are no longer present.

Once the level sending unit is installed , it needs to be connected to a gauge. T he below wiring should be followed :. If your gauge has color coded hook-ups, maintain this coding as you connect the sender and ground wires. Turn on the power to the level sending unit and gauge. Adjust the float and pay attention to the gauge, if the gauge has a reading that correlates to the position on the float the n the level sending unit and gauge are functioning properly.

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