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 |
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.
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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.
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I figure it's recommended, but is it necessary to have an empty or near empty tank of fuel before doing this job?
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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
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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
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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 |
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Again, many thanks. Need to upgrade my bifocals, I guess.
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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!
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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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