Did you see the dirt/corrosion/gunk under your terminal block that causes the prob
How to test the Fuel Sender inside the fuel tank ?
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Bollicky
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maxheadroom
- Supreme Being
- Posts: 1950
- Joined: Wed Feb 28, 2007 6:37 pm
- Location: Gloucester
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jackpiker
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Dicky&Dawn
Hello all,
Thanks to all who replied to this thread especially to Bollicky/Maxheadroom for the info and pictures
Successfully tested the sender unit itself and confirmed it was still working ok. This also confirmed the sender feed to the block connector at the top of the housing was also working and that, yes, the earth connector on the block was indeed stuffed. 5 minutes later I had a new earth lead attached to the block and the other end attached to one of the screws holding the housing onto the tank itself. Pushed the block connector that goes to the fuel guage back on and felt relieved when the guage started to work. Nothing fancy but now it works perfect.
BTW - Went back to the garage that serviced my Bongo and explained what had happened and how "I" fixed the problem. Owner was a bit red faced having previously said "we can fix anything with wheels". What made it funnier is he's a good friend and does historic rallying with me and a few mates so this would be something worth milking in the future especially when its his round at the pub
TTFN
Rich
Thanks to all who replied to this thread especially to Bollicky/Maxheadroom for the info and pictures
Successfully tested the sender unit itself and confirmed it was still working ok. This also confirmed the sender feed to the block connector at the top of the housing was also working and that, yes, the earth connector on the block was indeed stuffed. 5 minutes later I had a new earth lead attached to the block and the other end attached to one of the screws holding the housing onto the tank itself. Pushed the block connector that goes to the fuel guage back on and felt relieved when the guage started to work. Nothing fancy but now it works perfect.
BTW - Went back to the garage that serviced my Bongo and explained what had happened and how "I" fixed the problem. Owner was a bit red faced having previously said "we can fix anything with wheels". What made it funnier is he's a good friend and does historic rallying with me and a few mates so this would be something worth milking in the future especially when its his round at the pub
TTFN
Rich
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Michael
Fuel sender fix
My fix rectified the same fault without re-wiring the sender unit (if only my fault-finding had been as quick 
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1. Drill off head of external rivet (photo)
2. Carefully lever plastic terminal block off rivet shank and sender flange.
3. Remove both metal terminals from plastic terminal block (photo) and throughly clean them and external mating surface of sender unit flange with wire wool
4. Remove internal rubber insulation washer (and retain), cut off redundant shank of rivet and drill out the internal, large head of the rivet (which has the rheostat wire soldered to it) so as to make it into a washer.
5. Re-assemble using 4BA (or metric equivalent) brass nut, shake-proof washer and bolt in place of the original rivet making sure that the rubber insulation washer is replaced correctly (so as to insulate the rheostat wire from the sender flange) and that the plastic lip of the terminal block is correctly postioned in the hole for the same reason.
)1. Drill off head of external rivet (photo)
2. Carefully lever plastic terminal block off rivet shank and sender flange.
3. Remove both metal terminals from plastic terminal block (photo) and throughly clean them and external mating surface of sender unit flange with wire wool
4. Remove internal rubber insulation washer (and retain), cut off redundant shank of rivet and drill out the internal, large head of the rivet (which has the rheostat wire soldered to it) so as to make it into a washer.
5. Re-assemble using 4BA (or metric equivalent) brass nut, shake-proof washer and bolt in place of the original rivet making sure that the rubber insulation washer is replaced correctly (so as to insulate the rheostat wire from the sender flange) and that the plastic lip of the terminal block is correctly postioned in the hole for the same reason.
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Gozzy
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Bollicky