Broken fuel gauge

[Wilko70]

Hi fuel gauge broken, any tips on repairing Is it a major job? Also is fuel gauge checked on mot?

[Simon Jones]

You don't specify whether you have a petrol or diesel Bongo, but if it's the latter, chances are you just need to fit a new earth between the sender unit and the tank. Factsheet here:

http://www.igmaynard.co.uk/bongo/member ... sender.pdf

Fuel gauge is not part of the MOT, but if you run out of fuel during a test, then you will be issued with a failure.

[mikeonb4c]

You don't specify whether you have a petrol or diesel Bongo, but if it's the latter, chances are you just need to fit a new earth between the sender unit and the tank. Factsheet here:

http://www.igmaynard.co.uk/bongo/member ... sender.pdf

Fuel gauge is not part of the MOT, but if you run out of fuel during a test, then you will be issued with a failure.

That's interesting. Hadn't realised that petrol Bongos had a different arrangement to diesels. Wonder why that is.

[jaylee]

You don't specify whether you have a petrol or diesel Bongo, but if it's the latter, chances are you just need to fit a new earth between the sender unit and the tank. Factsheet here:

http://www.igmaynard.co.uk/bongo/member ... sender.pdf

Fuel gauge is not part of the MOT, but if you run out of fuel during a test, then you will be issued with a failure.

Yes indeed... & sometimes it could be a poor earth from the tank to the chassis... The fuel sender earths through tank, which in turn grounds to the chassis...

Loads of info on the forum too with regards to testing the actual fuel gauge from the sender connection at the top of the tank.. Not a difficult job!

[g8dhe]

There is no electrical difference between Petrol and Diesel gauges and lush projects reports the same part number so can't see why there would be any real differences.

[Simon Jones]

Maybe the diesel is no more prone to failure, but I don't recall hearing about anyone petrol owners having any problems. The petrol tank also contains a pump so perhaps there is an additional earth connection somewhere in the mix?

The part numbers do appear to differ slightly (at least for the 2001 onwards models)
Petrol: S38A60960 60960A GAUGE,FUEL TANK

Diesel: S38D60960A 60960A GAUGE,FUEL TANK

[g8dhe]

Yup your right Simon, there is a difference in the part number, I missed it!

[Simon Jones]

Just to follow up on this post. I can confirm that the petrol Bongo does have a separate earth and therefore should not require the same fix as the diesel version.

A few photos. The pipes are (from left to right): output from pump, return from engine, fume/ventilation with one-way valve, and overflow to the filler neck. The main filler pipe (not shown) goes in to the bottom of the tank. The earth is the left hand connection and the right hand one is for the pump, sender and low fuel sensor:



A view of what's below. The black wire is the sender and the grey wire would appear to be the low fuel sensor. The pump is fed by the red and black wires:



At the bottom of the tank there is a clever arrangement of a plastic reservoir which ensures there is a steady supply of petrol around the pickup pipe even though the fuel is sloshing from side to side with the movement of the vehicle:

[winchman]

I have a good spare diesel sender if any one needs one