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-   -   finally took care of my fuel gauge problem... (http://www.peachparts.com/shopforum/diesel-discussion/305771-finally-took-care-my-fuel-gauge-problem.html)

tip 09-25-2011 03:30 PM

finally took care of my fuel gauge problem...
 
Well, I had some extra time today so I decided to figure out one of the more annoying things on my '83 300D turbo. The fuel gauge does the usual jumping around, and never shows less than quarter of a tank. Really annoying, especially now that I'm driving it 50 miles a day.

I searched and read all the other posts related to this, and set to work. I decided to start with just cleaning the connector, but it was spotless. So I ended up taking out the whole sender and cleaning it. Thought I would share pictures of the process in hopes that it might help someone else out. Anyway, on with the pics:


removed the first aid kit
https://lh5.googleusercontent.com/-W...0/IMG_3740.JPG

top of sender:
https://lh4.googleusercontent.com/-k...0/IMG_3742.JPG
https://lh4.googleusercontent.com/-l...0/IMG_3743.JPG

not too bad, pins where nice and clean:
https://lh6.googleusercontent.com/-E...0/IMG_3744.JPG
https://lh6.googleusercontent.com/-e...2/IMG_3745.JPG


since there was no problem with the connection, I decided to remove the sender. Channel locks did the trick:
https://lh4.googleusercontent.com/-1...0/IMG_3746.JPG

https://lh3.googleusercontent.com/-9...0/IMG_3747.JPG


https://lh6.googleusercontent.com/-3...2/IMG_3748.JPG


fuel sender removed:

https://lh4.googleusercontent.com/-j...2/IMG_3749.JPG

bottom cap removed:
https://lh4.googleusercontent.com/-P...2/IMG_3752.JPG

https://lh4.googleusercontent.com/-y...2/IMG_3751.JPG


gently tapped the sender apart:
https://lh6.googleusercontent.com/-6...0/IMG_3753.JPG

yummy... I wouldn't be surprised if this has ever been apart
https://lh4.googleusercontent.com/-n...0/IMG_3754.JPG

https://lh6.googleusercontent.com/-s...0/IMG_3755.JPG

sender unit removed carefully:
https://lh4.googleusercontent.com/-o...2/IMG_3756.JPG

https://lh6.googleusercontent.com/-5...0/IMG_3757.JPG


gently cleaned with brake clean and a small toothbrush, with extra care cleaning the contacts:
https://lh4.googleusercontent.com/-2...0/IMG_3758.JPG

https://lh3.googleusercontent.com/-Y...2/IMG_3760.JPG

https://lh6.googleusercontent.com/-m...2/IMG_3762.JPG


reinstalling:
https://lh3.googleusercontent.com/--...0/IMG_3763.JPG

all set, lubed seal with some fresh diesel before installing:
https://lh4.googleusercontent.com/-J...0/IMG_3764.JPG

had to do something about this foam insulation:
https://lh6.googleusercontent.com/-o...0/IMG_3765.JPG

https://lh4.googleusercontent.com/-g...0/IMG_3767.JPG



I am very happy with the result, fuel gauge works PERFECTLY now! I didn't even know there was a low fuel light! Needle is rock solid and doesn't bounce anymore.

This was a fairly simple job, took about an hour taking my time, being careful. Very impressed with this design, lightyears better than the late model VW senders I'm used to working with.

Check one more thing off of the LONG list of tasks to do on this car.
https://picasaweb.google.com/1100516...71581288534018

LandYaghtLover 09-25-2011 03:37 PM

Congrats! Wish that would have worked for me. I am going to take mine out AGAIN. I am a gasser, but same issue. Mine never goes below a half-tank.

TchTchr 09-25-2011 04:29 PM

I took mine apart this morning in the wagon and it was in pieces. All the gunk shown at the bottom of yours explains why my clean inline filter filled up with crud in no time.

sd300td 09-25-2011 09:24 PM

I figure it's recommended, but is it necessary to have an empty or near empty tank of fuel before doing this job?

Biodiesel300TD 09-25-2011 09:44 PM

Quote:

Originally Posted by sd300td (Post 2797467)
I figure it's recommended, but is it necessary to have an empty or near empty tank of fuel before doing this job?

Not really, the lower the fuel the less mess potential there is. If you're quick you can pull it out and get a rag on it before it starts leaking and then make a run to the pan. There is a tiny whole at the bottom on the side of the tube. If you can plug it before it leaks you're golden, as long as the nut on the bottom is tight. If the hole is not plugged you can also pull the tube up until the whole is out of the fuel and let it drain out.

John Schroader 09-26-2011 03:55 PM

I am delighted to read this post. A couple of months ago my fuel gauge quit working. Been pretty busy and have not bothered to check the archives on how to repair it. But ------ I had somehow convinced myself that I would need to remove the entire fuel tank to access the unit. What a relief it is to see that, in the beloved MB tradition, repairs are straightforward. Love this car and surely appreciate this forum.:P

John Schroader 10-01-2011 11:13 AM

Just removed the fuel sender and am not certain how to remove the bottom plate (photo #10). Surely don't want to twist anything off that doesn't need twisting. Any good advice is appreciated.:D

TheDon 10-01-2011 11:22 AM

snap ring pliers or something to fit the two notches. A modified flat headscrew driver does the trick too.

I need to replace my sender in the 240D.

Great pictorial/DIY

Biodiesel300TD 10-01-2011 12:44 PM

Quote:

Originally Posted by John Schroader (Post 2801123)
Just removed the fuel sender and am not certain how to remove the bottom plate (photo #10). Surely don't want to twist anything off that doesn't need twisting. Any good advice is appreciated.:D

There is a nut on the bottom with a rubber collar on it. The nut is round but has two notches in it. A pair of needle noise work well or a modified flat head screwdriver as TheDon stated works too.

John Schroader 10-01-2011 01:18 PM

Again, many thanks. Need to upgrade my bifocals, I guess.

Biodiesel300TD 10-01-2011 01:19 PM

Quote:

Originally Posted by John Schroader (Post 2801176)
Again, many thanks. Need to upgrade my bifocals, I guess.

It's kind of a silly little nut. I don't know what the rubber collar is for, and why not just a normal nut?

Meowcedes 01-23-2012 01:57 PM

Thank you so much for all these pictures! I work so much better with visuals. I have an '85 300SD I've been slowly fixing up, and this forum has helped me out a lot so far. I need to start posting more feedback, so this is a start!

bipolardave 01-23-2012 02:36 PM

I haven't searched, but is the process similar for a W115?

Mine starts jumping around at 1/4 tank. Not always, and it tracks down to empty, but still something on my "to fix" list.


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