Fixing/Replacing Fuel sender? 1.9 Petrol Syncro

[Mickyfin]

My petrol gauge is not behaving, thus only showing just over half a tank when the petrol tank is full to the brim.

Also empty is way below the red.

Any advise on how to fix, or replace the sender in the tank would be appreciated. I'm guessing its a tank out job? If so, this would not be a problem, unless gearbox needs to be dropped to allow tank removal?

Thanks in advance.!

[Mickyfin]

Anyone?

[ninja.turtle007]

Fuel sender is behind drivers side rear wheel if yours is a LHD.

Most are not accurate. Reset your trip meter when you fill up and refill at 400KM.

Basing that on 29 KPG that should leave you with 8l in reserve (70L capacity). Adjust accordingly once you have done a few tanks and worked out you KPG.

[Aidan]

if it's working partially then get the contact cleaner spray out and liberally clean up the plug and socket in the wheel arch, be very very careful removing the plug from the socket as chances are the pins are rusted together, if you break the wires coming out of the tank then it's new sender time which isn't cheap and is a pain to do, basically the extra ressistance caused by corroosion is giving you false low signal I'd say
ps when I did mine a couple of months ago it took me more than 10 mins to seperate the plug from the socket using penetrating fluid and just enough force not to break anything - but it's back to accurate now

[Mickyfin]

Cheers guys, will take a look, and see what I can do then, thanks again.

[Mickyfin]

Anyone know these?

[ninja.turtle007]

Yes, that the fuel sender connector. Not sure what the other connector is for although mine has it too with nothing connected.

[Mickyfin]

Cheers Tom, now to try and unplug it without breaking it. Guess soaking it in wd40 will help loosen it hopefully.

As to the other plug, I guess its something related to an optional extra maybe?

[Mickyfin]

So let me get this straight, the fuel sender connection in the above photo is a spade connection under that rubber boot? Does it slide/unclip by pulling outwards, or sliding is against the fuel tank? Kind of want to know what Im dealing with before I attempt to unplug it. Has anyone got a photo of this connector with the plug removed please?

[Aidan]

it's a 2 pin moulded plug, pulls straight out, ie upwards toward rear of arch, if you pull the rubber boot back you will see the plug has two little tabs at the edge you can get a prybar in there and gently start to lift the plug with them

the other connector clipped to the wiring loom is for a decoupler

[Mickyfin]

Excellent, cheers mate, I will take a look later.

[Mickyfin]

if it's working partially then get the contact cleaner spray out and liberally clean up the plug and socket in the wheel arch, be very very careful removing the plug from the socket as chances are the pins are rusted together, if you break the wires coming out of the tank then it's new sender time which isn't cheap and is a pain to do, basically the extra ressistance caused by corroosion is giving you false low signal I'd say
ps when I did mine a couple of months ago it took me more than 10 mins to seperate the plug from the socket using penetrating fluid and just enough force not to break anything - but it's back to accurate now

Cheers for that Aidan, managed to get the connector off ok, cleaned as best I could, then gave it a good spraying with electric contact cleaner, so hopefully next time I fill up, fuel gauge will show true reading.