240D - 460,000 miles

I took out my fuel tank because my tank screen kept getting clogged. I had some serious "build up" in the bottom of the tank which I had boiled out.

I removed the sender but my "buddy" had cut the lines because he couldn't figure out how to get the connector off the top of the tank (after he cut it I showed him the two screws in the first aid kit box!).

While the tank was being cleaned I replaced all the rubber hoses out back and proceeded to clean all the "varnish" off the sending unit.

I used "easy crimp" electrical connections to reattach the electrical leads to the connector. (I know the first question will be to make sure I correctly connected the leads back to the correct wire - YES, they are connected correctly)

Reinstalled the tank, screen, hoses, sender and connection. As soon as I turn the key to "Acc" the gauge jumps to FULL.

I thought maybe the sender needed to "recalibrate" so I filled her to the brim and drove her.

NOPE, stuck on Full.

I used Parts Cleaner and Brake Parts Cleaner to remove the varnish on the sending unit . . . could that have caused a problem.

Stumped

__________________
1982 240
460,000 miles total
140,000 on Rebuild