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Parts
List
1. Fuel Level Sender 1
2. Float Arm 1
3. Gasket and Hardware Kit 1
4. Bolt-on Installation Kit 1
Weld-on
installation kit (optional) P/N 22690
CAUTION:
Read these instructions thoroughly before making installation. Do not deviate
from assembly or wiring instructions. Always disconnect positive battery lead
before making any electrical connections. If in doubt, please contact your
dealer or VDO North America at (540) 665-0100.
Refer
to the VDO North America catalog for matching fuel gauges. The unit can be
adjusted to read accurately in tanks from 6" to 23" deep. For sender
adjustment, refer to Table 1 and Fig. 2.
I. Measure depth of the fuel tank.
Locate this dimension in Column "A" of Table 1. Column "B"
then shows the length from the underside of the sender flange to the center of
the float pivot. Column "C" shows the distance from the center of the
float pivot to the center of the float ball. For example, a tank 12" deep
would need a measurement of 6" from the flange to the pivot, and 7.8"
from the pivot to the float.
II. For tank depths up to 15-1/2"
it will be necessary to eliminate a part of the assembly. (See Fig. 1) Proceed
as follows:
1.
Remove nut "a", washer "b", and ring terminal "c"
from the underside of the mounting
flange.
2.
Remove two screws "d" and discard.
3.
Remove two screws "e" from the plastic housing and reserve for later
use.
4.
Carefully remove bracket "f" from the plastic housing and discard.
Replace with bracket "g" in the housing and loosely re-install the
two screws "e" into housing.
5.
Slide housing up or down until the proper dimension from Table 1 is reached,
then tighten screws securely.
6.
Replace ring terminal and hardware.
CAUTION: Do not over tighten hardware, to avoid damage to the threads.
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CAUTION:
When installing the float arm into the sender body, make sure the float ball is
to the right side when you face the unit, as shown in Fig. 1. If installed to
the left, the fuel gauge will read "full" when the tank is empty.
III. For tank depths of 16" to
23°, no disassembly of the sender bracket is necessary.
1.
Remove ring terminal as instructed in Section II, above.
2.
Loosen two screws "d" and adjust the plastic housing up or down until the proper dimension from Table
1 is obtained, then retighten screws securely.
3.
Re-install ring terminal and hardware, and tighten all hardware securely,
avoiding over tightening.
IV. To install the float assembly,
loosen screw "h", remove the short piece of rod, and discard. Insert
the float rod until the proper length "c" from Table 1 is met, then
tighten the screw securely. Carefully cut off any excess rod with a bolt cutter
or similar tool, taking care not to damage the assembly.
NOTE: Make sure the float is installed
as shown in Fig. 1.
If
installed backwards, the fuel gauge will indicate "full" when the
tank is empty, and "empty" when the tank is full.
VDO
North America recommends that the fuel sender and the fuel gauge be wired
together and checked for compatibility prior to installing fuel sender into
tank.
SAFETY PRECAUTION: When making modifications to fuel tanks, it is essential that the
tank be removed from the vehicle, and that it is empty, clean, and dry. After
drilling, make sure all chips and other foreign matter have been removed from
the tank.
V. Refer to Figs. 3 and 4 for
installation of the fuel sender assembly into then tank. The sender flange is
designed to fit a standard SAE hole pattern.
CAUTION:
Before drilling any holes into tank, place the sender assembly on top of the
tank to judge proper hole placement allowing float arm clearance inside of tank.
1. Cut
a 2.322" (59mm) hole in the top of the tank.
2. Pick
up fuel sender and slide the rubber gasket up to the bottom of the fuel sender
flange. Next, slide the second flange over fuel sender to bottom of rubber
gasket. Align the pre-drilled holes in mounting flange and rubber gasket with
those in fuel sender flange. Use 1" screw to connect top flange, gasket,
and mounting flange. Tighten until there is .708"(18mm) between flanges. DO
NOT TIGHTEN DOWN COMPLETELY.
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3. Slip
the fuel sender assembly into the 2.322" (59mm) hole in the tank, turning
assembly until it goes into the tank.
CAUTION:
Make certain float arm has a clear field of motion before tightening screws in
flange assembly.
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