I made this tool to remove the FSU without damaging the part. It worked great. Hopefully, problem solved. UPDATE: Seems that all I needed to do in order to get my gauge to read full is rotate the FSU slightly so that the two holes are at 12 and 6 o'clock. Just filled up and the needle is on F. RESULT!
Last edited by Ryanoscerous : 06-13-2007 at 06:43 AM.
Is this tool you made a necessity or does the FSU easily come off with minimal effort. And how do you rotate it so that holes sit at 6 and 12 o'clock? Thanks
My guage reads 7/8 full when I fill up and electronic reading says I have 18.4 gallons in the tank with 300 mile range.
Would you mind writing up what is involved in the R&R/adjustment of the FSU? Nice to add this to one of the stickies but if you've not done it, the pics by themselves don't help too much.
Take care and enjoy the ride,
Greg
__________________ When you learn from your own mistakes, that's experience.
When you learn from the mistakes of others, that's wisdom.
When you fail to learn from any mistakes, that's government.
My pleasure. I was unable to move the FSU myself without the aid of some type of tool. Of course the tool is commercially available for a premium. My problem was similar but more severe. I could never get the gauge to read more than 3/4ths full.
Then use the tool (home-made or otherwise) to rotate the FSU until the two holes are properly aligned (12 & 6) or until your gauge reads full. I fully removed the FSU and cleaned the contacts with 90% rubbing alcohol (with little result).
I would recommend doing this at 1/2 tank or less to minimize drippage, then fill her up and admire the needle on F!
__________________
Everything should be made as simple as possible, but not one bit simpler.
Albert Einstein
Last edited by Ryanoscerous : 11-29-2007 at 06:54 PM.
Just to add something......... The fuel sender can easily be removed with a large channel lock pliers. Just open them up and grab the outside of the unit and twist to the left. It is not in very tight and will come right out.
My unit already was at 12/6 so I took it out and bent the float arm. Had pretty much no effect.
It is easy to tell that the VDO rheostat is what the problem is. You can not get just the rheostat and must buy the whole unit. That is a huge rip off. The rheostat would be simple to replace if available.
Homemade Tool to Remove Fuel Sending Unit 
Linear Mode
