Homemade Tool to Remove Fuel Sending Unit

27131 Views 19 Replies 14 Participants Last post by barrylisa, Oct 2, 2011

Ryanoscerous

Discussion Starter · Jun 12, 2007 (Edited)

2

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!

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s2addict

· #2 · Nov 29, 2007

how do you rotate FSU?

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.

Check Codes

· #3 · Nov 29, 2007

Hey, Ryan, mother of invention, indeed.:thumbsup:

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

Ryanoscerous

Discussion Starter · #4 · Nov 29, 2007 (Edited)

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.

It is simple, just remove the trunk liner...
http://www.benzworld.org/forums/w210-e-class/1219609-trunk-liner.html?highlight=remove+trunk

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!

Check Codes

· #5 · Nov 30, 2007

Thanks, it's in the Tips sticky...along with the Trunk Liner one.

s2addict

· #6 · Nov 30, 2007

thanks

will give this a shot this weekend.:thumbsup:

jh225

· #7 · Nov 30, 2007

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.

Hi Fi

· #8 · Jun 22, 2008

The part of the trunk liner to take off is the trunk liner right behind the back seat not the fender side.:thumbsup:

bonghc

· #9 · Oct 19, 2010

I am a Newbie here, recently I bought a second hand 1996 E200 W210 Merz, I hv a few problem with the car, let's start with the fuel gauge first. My fuel gauge reading, with the fuel gauge sensor connected it reads 80% full regardless the amount of fuel in the tank, with the gauge disconnected the meter reading dropped to 30%, what is the problem with my fuel tank reading? is it the problem with the gauge sensor or the cluster fuel meter? can any expert give me some advice?

[email protected]

· #10 · Oct 19, 2010

That is very clever-------nice job!!!!

bonghc

· #11 · Oct 19, 2010

Why clever???? what nice job??? I still haven't find out the problem yet, I still need expert advise. Please help!!!

[email protected]

· #12 · Oct 19, 2010

bonghc said:
Why clever???? what nice job??? I still haven't find out the problem yet, I still need expert advise. Please help!!!

I am sorry, I tend to look at things in a positive light.

The gent that started this I think is the very clever one for thinking out of the box and producing a tool---------------However you on the other hand must be related to "OL" and I still think of you as a rather foolish SOB who hasn't learned anything from this post.

Maybe in your case you should first try to fill the tank!!

raymond-

· #13 · Oct 19, 2010

steady....no need to go there.

BioNerd

· #14 · Oct 20, 2010

Mine jumps a little bit, most of the time reads well before it hits 1/2.
Should I give it a try?

Cactus_Jack

· #15 · Jun 2, 2011

My fuel gauge was at a consistant 1/8 less than full (always seemed to read 1/8 short). This went on for months. After finding this sticky, I checked the position of the indicators on the sending unit but I found it was already at the 6 & 12 o'clock positions. I decided to remove the sending unit and reinstalled it with indicators at 6 & 12 o'clock positions and checked fuel gauge, it ready exactly as before I removed it. I then backed off a little and set indicators to approximately 5 & 11 o'clock, and checked the fuel gauge and it was now reading 1/8 more. I then drove to gas station and filled up the gas tank and the needle went all the way to "Full" on fuel gauge. Since then, I am still averaging the same MPG as compared to before the adjustment.

The jist of it, it doesn't appear that the fuel sending unit indicators need to be at the 6 & 12 o'clock positions, or at least in my case. So if you are getting shorted by around 1/8 of a tank by the fuel gage try adjusting the fuel ending unit positions to approximately 5 & 11 o'clock. My guess is you can adjust if you are off around the same as I was. You may want to try this before you drop at least $135 on a new fuel sending unit.

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Plutoe

· #16 · Jun 2, 2011

Regrettably, you missed the COMPLETE point.

The two pin socket positions are 180 degrees from one another----------now with your sending unit not securely fit to the tank, don't come whining back------why do I have a gas smell in my car!!!

KMani1

· #17 · Jun 2, 2011

6 & 12 and 5 & 11 O'clock still 180 degree to me same as 9 & 3 O'clock.

Plutoe

· #18 · Jun 2, 2011

Loosening once torqued to get a certain pin position is not a requirement.

Tightening and sealing the sensor is what is important.

Who cares where the pin positions are once tight----The point is you don't loosen the sensor to get a certain finished pin position.

Kajtek1

· #19 · Jun 2, 2011

Plutoe said:
Loosening once torqued to get a certain pin position is not a requirement.

Tightening and sealing the sensor is what is important.

Who cares where the pin positions are once tight----The point is you don't loosen the sensor to get a certain finished pin position.

English, Please

barrylisa

· #20 · Oct 2, 2011

Fuel gauge not reading full

I have a W210 E240 1999 model. I had a fuel gauge that would not read accurately.
From the technical forums here with multiple advice, I removed the fuel sender unit and cleaned all the slide contacts with a pencil eraser. No special tools required, no bending necessary. Worked exceptionally well and now reads correctly.
This was an amazingly simple job to do. Thanks to those who figured this out and saves on buyinbg a new sender unit:thumbsup:.

PS I have learnt heaps from this forum but this has been my second attempt at sorting out a problem and had to at least provide some feedback.

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