Proper fuel sending unit installation

T he below wiring should be followed :. If your gauge has color coded hook-ups, maintain this coding as you connect the sender and ground wires. Turn on the power to the level sending unit and gauge. Adjust the float and pay attention to the gauge, if the gauge has a reading that correlates to the position on the float the n the level sending unit and gauge are functioning properly.

If not, this may mean that the level sending unit or gauge is not functioning properly. See our previous post on troubleshooting your boats fuel level sender to address the issue. You can count on KUS customer service and sales representatives every step of the way from initially selecting a liquid level sending unit to guiding you through the installation process.

Many of the worlds leading marine companies rely on KUS for affordable yet reliable level sending units that will stand the test of time given different operating environments.

Get in touch with KUS today to learn how we can be your marine level sending unit supplier! In Blogs. By Trevor Mahoney. Note: If you are unsure how to perform any of the detailed procedures, seek professional assistance.

Gasoline is extremely flammable. Keep tank area free from sparks and flames. Avoid using power tools around fuel vapors which are easily combustible. Step 2 Determine the proper sending unit length for your tank by measuring from the inside bottom to the outside top of the tank.

Step 3 Order your level sending unit and be sure to select the proper length and type. Step 4 Once you receive your level sending unit and gasket mounting kit you can begin the installation process. Step 5 Position the new level sending unit above the tank, aligning the screw hole pattern in the mounting plate with the hole pattern at the top of the tank.

Step 6 Install the level send ing unit with the aligned gasket by inserting the down tube into the tank. Step 7 Secure the level sending unit to the tank by tightening the mounting screws into place using a star shaped pattern.

Step 8 To ensure the level sending unit is proper ly install ed , a leak test need s to be conducted. Step 9 Once the level sending unit is installed , it needs to be connected to a gauge. T he below wiring should be followed : 1 Connect ground pink wire from the KUS sending unit to a common grounding hook-up. Step 10 Turn on the power to the level sending unit and gauge.

Contact Us by Email. Prev Next. Gasoline and gasoline vapors are very dangerous. Be certain to keep sparks, hot items, and electric motors away from the gas tank and fill neck. We had run our gas tank down to below a quarter tank knowing we would be draining the tank. Our first step was to remove the gasoline from the existing tank in the car. A quick trip to Harbor Freight netted us a hand-operated transfer pump that was safe to use with gasoline. We also picked up a new 5-gallon gas can while we were there.

The hand-operated transfer pump did just that; it quickly transferred the gasoline from the tank to our new gas can. Next, we needed to remove the original threaded filler neck. Removing this threaded collar from the tank is a notoriously difficult task. We soaked the connection with PB Blaster penetrating oil for a couple days hoping to loosen things up. You can use a spanner wrench. Sure enough, with a little effort, our threaded collar was removed from the tank.

Next, we went inside the car and removed the small panel in the floor that covers the fuel-tank sending unit and removed the single screw holding the gas gauge wire. Rolling under the car on a creeper we were prepared to remove the four bolts that hold a Ford gas tank in place.

As it turns out a previous owner figured Ford overbuilt his cars, so he only used three bolts to hold the tank in place. We removed the three bolts and commenced to wrestle the tank out of the car. While the tank does come out, we can tell you it is a tight fit and the wrestling match experience is enhanced by dirt falling in your face. With the old tank on the floor, we did a closer inspection. However, the original gas gauge sending unit had broken headless screws and the fuel pickup in the front of the tank had some epoxy sealant around it.

The tank itself was remarkably clean inside for an year-old gas tank. But after the assessment we were certain installing a new tank was a wise decision. The new tank varies from the original because it has a fuel fill outlet designed for a hose connection rather than the threaded original and the fuel pickup on top of the new tank as opposed the front fuel pickup on the original.

Finally, the new tank also holds a couple of extra gallons as it is a bit deeper. Before we could install our new tank, we had to adjust and install the Classic Instruments fuel gauge sending unit , following the instructions we had that set up and installed. We also had to install the fuel pickup and vent fitting in the tank. Once again, following the directions I know, crazy as it seems, directions actually do help we cut our custom fuel pick up to the proper length.

This small hose fit our original metal fuel line in the car. We also ran a fuel-sending unit ground wire from the fuel gauge sending unit at this time. These rubber pads are not required but our original tank had body webbing so we felt a rubber pad was a good idea.

With those connections completed we cleaned and painted the floor above the tank and when the paint was dry the second wrestling match began.