The V8 fuel gauge can get unreliable. Fortunately, it is very simple to fix, requires minimal tools, and about an hour of your time.

 

NOTE: Have your petrol tank as empty as possible and have the car windows down so vapors don’t collect inside the car.

 

 - You need an 8mm spanner, a 14mm spanner, a small screwdriver, a medium Phillips head screwdriver, methylated spirits, a clean rag, a clean work surface, and about an hour.

 

 

 

 - Open the boot, and remove any junk. Gently pull the cover panel towards you, it unclips quite easily to expose the top of the fuel tank. You can remove the clips at the bottom and take the panel out completely, but I didn’t bother.

 

 

 

 - Now the tank is exposed, remove the two plugs and cables towards the right.

 

 

 

 - To remove the gray clip from the sender housing, you need to use a small screwdriver to open the catch tab on the other side of the plug, a bit fiddly but easy once you know what you are looking for. This is looking at it AFTER removal so you can see how to release it.

 

 

 

 - Undo the 8 bolts holding the sender unit using an 8mm spanner. Gently start to lift and slide the sender unit out.

 

 

 

 - The sender is very long but gently does it. Here it is about halfway out.

 

 

 

 - Here is the complete assembly removed.

 

 

 - Undo the two screws and 1 nut that hold the Yellow, Red, and light Brown wires on. No need to worry about the Blue one.

 

 

 

 - Undo the two 14mm bolts that were under the Yellow and Brown wires. A bolt should drop out the other end allowing you to slide out the tube.

 

 

 

 - After removing both tubes, the bottom locator will just slide off.

 

 

 

 - Unscrew the center tube from the top housing.

 

 

 

 - Slide the outer tube off, then unscrew the exposed inner tube - I set the outer tube back on just for the picture to show there are two tubes that were removed to expose a center probe.

 

 

 

 - After removing the two outer tubes, undo the nut (above right) and remove the central probe.

 

 

 

 - Soak part of the clean rag in methylated spirits and wipe all the tubes and the probe. Methylated Spirits mix with petrol so it won’t contaminate the fuel.

 

 

 

 - Now comes the important bit. Inside the smaller center tube near the bottom (left-hand side in the above pics) is a locating piece for the probe.

 

 

 

- Gently insert the probe into that end of the tube and push to slide the locator towards the other end about 1 cm (1/2”). This will ensure the locator catches the end of the probe as you re-assemble, holding the end of the probe firmly in place and not letting it touch the sides causing the fuel gauge reading to jump about.

 

- Re-assemble it all and fit it back into the tank. It’s a bit fiddly to get back in properly, the bottom tends to catch inside the tank, but persist and be gentle and it will go back in correctly. Replace and tighten the bolts, re-connect the plugs, and the job is all done!

 

 

CONTRIBUTORS

 - Peter (Soarer Central)

 - @Skinnyboyash