Anyone done the 'loose wire on Fuel Sender' fix for E36's?

[neil_bolton]

I've got a fuel gauge that is constantly reading zero, even once fully fuelled, and having done my searching through the esteemed E36coupe site, I've deduced that it is most likely the feul sender which has a loose black cable, meaning that the fuel sender doesn't work correctly.

The instructions are pretty much comprehensive, however having never really done something involving fiddling with the fuel tank I've a quick query or two if nobody minds?

1. I obviously disconnect the battery, yes?
2. When I disconnect the fuel pipe, I need to use a new jubilee clip to reattach it, yes?
3. When soldering the wire back on, can I strip the cable back a mm or so, and then put a blob of solder in the thingy to solder it? Is this the best way?
4. When refitting the fuel pump, should I use a new gasket, or will the existing one be alright?
5. I assume I need good ventilation, but what would somebody recommend to cover the tank hole whilst I'm off soldering (somewhere else)?

Sorry for the seemingly simple questions, I just want to check before I start blowing myself up!!!

Ta in advance!

[ChrisRS]

http://www.youtube.com/watch?v=gK1YEn5gfxg

[neil_bolton]

ChrisRS said:

http://www.youtube.com/watch?v=gK1YEn5gfxg

Git

[Talkwrench]

neil_bolton said:

1. I obviously disconnect the battery, yes?

Personally, I wouldn't bother. You'll end up with radio codes needed and all sorts of nonsense. If the ignition is off, the wire is not live so everything will be fine.

1. When I disconnect the fuel pipe, I need to use a new jubilee clip to reattach it, yes?

Not a jubilee clip, a fuel pipe clip. Jubilee clips are a little too inflexible and tend to dig into the rubber hose. Use a smooth, round fuel pipe clip to eliminate this problem.

1. When soldering the wire back on, can I strip the cable back a mm or so, and then put a blob of solder in the thingy to solder it? Is this the best way?

Make sure its free of all oil, grease or petrol first. Make sure you use either multicore solder with flux up the middle (most common) or use plenty of separate flux. Heat the connector and wire first and let the heat of the wire melt the solder, not the soldering iron. It should flow freely.
I always slide some shrink wrap tubing over the wire first, then shrink it over the joint when its soldered.

1. When refitting the fuel pump, should I use a new gasket, or will the existing one be alright?

The existing one may be alright but I'd buy a new one and replace it anyway.
You really don't want a weeping seal here. The car will permanently stink of petrol!

1. I assume I need good ventilation, but what would somebody recommend to cover the tank hole whilst I'm off soldering (somewhere else)?

I use a clean, lint free cloth to temporarily cover the hole. A nice white cotton shirt is ideal but the colour isn't so important.....

Sorry for the seemingly simple questions, I just want to check before I start blowing myself up!!!

Good luck... oh, and best not smoke whilst completing this job!

Ta in advance!

[neil_bolton]

That is superb advice - it's just the sort of small questions I have with these sorts of jobs that I don't really get to glean from the (very helpful) FAQ's that are dotted about.

Obviously I'm happy to give it a go, but these sorts of tips are what makes me all that less nervous about cracking on with it.

I owe you a beer

[neil_bolton]

Ooh, another quick question if you will: re the soldering...

This 'shrink wrap' - where would be the best place to get this: indeed the same with the fuel pipe clips?

The T-shirt - does it need to be damp - or just as it comes?

[Gad-Westy]

neil_bolton said:

Ooh, another quick question if you will: re the soldering...

This 'shrink wrap' - where would be the best place to get this: indeed the same with the fuel pipe clips?

The T-shirt - does it need to be damp - or just as it comes?

Hi Neil, Good luck with this. Shrink Wrap is available from RS, Maplin etc... or I can send you some if you want. You'll need a heat gun or Hair dryer (if you're that way inclined )to shrink it afterwards.

Fuel clips are probably available at Halfords. Otherwise any decent Motor Factors will have them.

Edited by Gad-Westy on Wednesday 3rd October 09:32

[Talkwrench]

neil_bolton said:

Ooh, another quick question if you will: re the soldering...

The T-shirt - does it need to be damp - or just as it comes?

Well, personally I've always been fond of a wet T-shirt when adorning the female form....
but for covering the fuel tank, dry will be fine. Its just to keep the dirt out.

[peaktorque]

Done this very job on my E39. Easy-peasy (on the '5' anyway, not sure on the '3')!