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Where do i find the wires for the fuel sender unit for my tank

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Posted on Jan 02, 2017

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SOURCE: Fuel tank parts

Don't get a new one!!! If you're anyway handy, drain the tank, slip it off the bike & turn it upside down. Scribe a mark on the body of the unit to the tank to ensure you get it lined up again rebuilding. Unscrew the 4 retaining screws holding the sender unit in place. The rubber seal can be used again but examine it first. Carefully remove the sender unit, it's crooked in parts so you need to twist it at strange angles to get it out. Once it's out you will see the float/metal rod attached to a black bakealite holder. There is a tiny star shaped washer holding it in place, very easy to lose. Prise off the washer. Keep it safe. Upon inspection of the bakealite holder(potentiometer) you will see the metal rod has elongated the hole and thus sends a wrong signal to the fuel gauge on the dash. To counter this, get yourself some plumbers tape, the very thin stuff, and wrap it round the metal bar where it goes through the potentiometer, the part that is most worn. The trick is to get the metal rod to sit evenly & square to send the correct signal to the gauge. You may have to add or deduct some tape but make sure the float/rod moves freely before you rebuild it. This sounds gimmicky but in essence it's really handy and you save £50 on a new sender unit. Before you refit the little washer, gently squeeze it between a flat pair of pliers to tighten the little gripper teeth, then refit it. Press it home with pointy nose pliers. To test it you can attach it to the multiplug on the bike and move it manually with your hand whilst watching the dash. You should have a working fuel gauge. Mines been repaired like this for 4.5 years and it's as accurate as it was before it went wonky. Hope this helps.

Posted on Jun 01, 2009


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1 Answer

Petrol ? gauge not going up to show quantity

If you're sure that all fuses are okay, it's probably the sender unit at fault.

The sender unit is part of the fuel pump which, on most cars, is in the fuel tank.

However, also check the wiring that goes to the fuel tank - you should be able to see the wiring on the TOP of the fuel tank - the connections.

It's unlikely to be your fuel gauge at fault - probably the sender unit.

Jan 23, 2016 | Cars & Trucks

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Gas gauge won't work and it has a full tank of gas. Is there a fuse I can change.

There might be but it is unlikely a fuel gauge is fused alone; usually if it is a fuse other things will stop working too but I suggest you are guided in this matter by your car handbook.

Problem is probably wiring and in particular the grounding of the fuel tank sender unit. It could be a faulty sender but they are usually quite reliable.

Test by disconnecting the wire from the sender unit at the fuel tank and short to a good ground and the gauge should read full. If the gauge wire is in a block with other wires it will be necessary to positively identify the gauge wire before testing.
If the gauge reads refit the wire and duplicate the ground wire to a known good ground. If the gauge still reads the fault is a bad ground to the tank sender unit and if it doesn't the sender unit itself is probably faulty.

If grounding the gauge wire does not produce a reading the fault is the wiring to the tank, the supply to the gauge or a problem with the gauge itself.

Feb 06, 2015 | Cars & Trucks

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Remove fuel pump from vt commodore

Remove and drain as much fuel as possible from tank.
raise vehicle on hoist or car stands.
disconnect earth wire from tank securing clamp.
position correct jack under tank
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slowly lower fuel tank and disconnect all fuel lines from sender unit.
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The wire between the dash and the fuel tank is connected to ground somewhere. there is a control that fails too but if the control failed the temperture gauge also won't work. The wire can get in troble inside the tank too as if someone tried to steal the gas with a hose. if you can disconnect the connector ( wireing ) at the fuel tank and turn the key on and the gauge goes to empty you know the troble is inside the tank and the pump sender unit will need to be removed from the tank to correct the problem or even the gauge unit replaced.70198425.jpg

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Perhaps you might consider the sending unit in the gas tank.

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ONE of 3 things
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Fuel gauge shows quarter tank then the low fuel light comes on showing eighth of tank

Most likely it's one or BOTH fuel level sender units in the fuel tank (there are two float units, one with the fuel pump). Located under the rear pass seats on the driver's side and another on passenger side (seats need to be moved out of the way to get to them - four 14mm bolts with each seat).
You'll see the 8mm screws holding the units in place.
Wiring Diagram:

8047594.jpg In this diagram, the sender units are wired in series (one or both may be causing your problem). The sender units are simple potentiometers (rheostats) & their combined resistance tell the microcomputer in the instrument cluster what the fuel level is, then It tells the fuel gauge where to put the needle. Inspect your wiring connectors to these sender units first. These sender units can be ordered/purchased at a Hyudai Parts Department. I don't believe there are any after-market units available - they are a dealer item.

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1 Answer

I need to replace the fuel pump in my 940 Volvo.

Disconnect battery ground strap before beginning to work on the fuel/electrical system. Do not smoke or have anything in the area which can ignite or cause sparks

  1. Drain enough fuel from tank to prevent spilling, no more than 4 gallons (16 liters) of fuel should remain. Use suitable pumping equipment.
  2. Remove floor mat and panel from trunk.
  1. Disconnect wiring harness connector to sending unit. Remove wires from connector.
  2. Disconnect ground wire to sender. Push wires through grommet.
  3. Remove cover for access to tank sending unit.
  1. All models: Disconnect from the fuel tank sending unit:
    1. Breather hose C
    2. Return hose A
    3. Supply hose B
    4. Filler hose D
    5. Wiring harness from clip E
  1. Clean area and unscrew fuel tank sender/pump cap or equivalent. Remove tank sender/pump and seal.
  2. Remove pump from sender/pump assembly.
  1. Inspect the pump for damage, feed pump hose and wiring for wear. Replace as needed.
  2. Install new pump to sender/pump assembly.
  3. Install rubber seal in neck of tank. Lubricate inside of seal.
  1. Install fuel tank sender/pump unit. Align it with the moulded joint (arrows) on tank.
  2. Apply rustproofing compound to exposed metal portions of tank sender.
CAUTION : With tape or rubber caps, protect fuel sender openings from overspray.
  1. Torque fuel tank sender/pump lock ring to: 22 ft-lb (30 Nm)
  2. Reassemble components in reverse order. Use tie straps to secure all hoses and wiring.

Jun 04, 2009 | 1995 Volvo 940

1 Answer

Pajero NK87 petrol guage not working, shows empty even when tank is full

Sounds like the Fuel sender unit in the fuel tank needs replacing however you may want to check that the electrical plugs are contacting properly,Check that the gauge is working by putting a piece of wire from the sender unit wire to the chassis,at the fuel tank sender unit plug,Turn ignition on while watching gauge if it moves toward fill turn ignition off and remove wire to chassis.If gauge moves it means from the fuel tank to fuel gauge is intact and not your problem.

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1994 grnd cherokee jeep

unplug the wire from the fuel tank sender unit and earth that wire to the chassis. switch the ignition to the on position,not crank, and see if the dash gauge starts to move to the on position, if it does the problem is at the tank sender unit, assuming that the wire to the gauge is not damaged. sometimes just pulling that wire off can re-establish a decent contact when you reinstal it.also the tank sender unit should have a good earth.

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