Fuel tank sender and feed replacement.

With so much clambering about in the back working on the old bus and with it being 27yrs old and all that, the pick up and return pipes on top of the sender have rotted through and were leaking fuel all over the top of the tank.

Not pretty but relatively straight forward.

You need a new sender unit, readily and cheaply available for a 200Tdi Discovery, 2 new 8mm sealing olives and if you're feeling flush then really go to town and get two new pipe unions to replace the old ones, mine were grotty but would go again.

New sender unit, it comes bare with no seals or sealing olives so be warned!

The old sender with porous pipes.

 Grab 2X 14mm spanners and undo the unions.

Ooops, but yeah it was expected.

Now then, remember where I told you that the new sender came bare, well this is the part where you need to get yourself 2 new sealing olives as your's will be the same as mine and they'll be rusted solid.

I didn't have days to wait for new ones to come via mail order and my local hardware stores didn't have the olives that small on the shelf so I had little choice if I wanted to get it up and running quick smart but to buy an 8mm in line coupling just for the olives.

Turned out just fine to be honest and just as cheap as buying a pack with more than I needed that would go to waste as I only needed 2 olives.

Just undo the small wiring plug and pop the earth wire off the sender.

Undo the big plastic nut and as you pull the old sender out the rubber seal will do it's best to swan dive into the tank just to piss you off so be prepared to grab it and pull it out with the old sender.

 Clean it all up and smear a bit of grease around the seal and pop it back in the neck and grease up the sender ready for fitting and pop it in from the top, making sure it is pointing in the right direction and wind the big nut back on and refit the unions and electrics and job is a good un, the best piece of advice I can give is that you need to fit the big plastic nut and just before you nip it up, turn the sender counter clockwise about 30 degrees and then as you nip up the plastic nut, it will spin the sender and when it is pointing correct then it is tight enough.

 So that's that jobbed, still got more welding on the horizon on this project but we are getting there bit by bit.

Thanks for looking.