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Jim,
I was where you were before. Some wonderful 99 owner gave me some directions and pics for repairing the sending. I searched and found them. Here are the directions, and I have the pics if you'd like them.
Rgds,
Brently
I have attached a ZIP file with the photos of rewinding the sender. Just a couple of notes:
1. I attached the new wire to the cut off end of the old wire with a cut off piece of a blade connector as you will see from the photos. It has worked just fine. I didn't even try to solder it, but this might work. I wasn't sure if the solder would adhere to the Ni-Cr wire so I didn't try it.
2. The number of windings of the wire is very important, within approx. 2-3 windings. Painstakingly count the number of old windings as you take them off .
3. You can test the sender out of the tank before you reinstall it. It may not be precisely like the original, but with a little care, you can get it very close. The one I did for my 99GLi works perfectly and I can't tell any difference from the original. The one on the '80 900 doesn't quite get all the way down into the red at "empty" because I added a few too many windings at the beginning. The key to remember is that at high resistance from the sender, the needle on the fuel gauge will indicate a high fuel level. The less resistance, the lower the fuel level. In other words, at the beginning of the windings where the wire connects to the sender, there is less resistance, thus a low fuel level. Out at the far end of the windings is where the fuel level is high. So when the windings are broken as on the worn out sender, you get no continuity = max. resistance. Therefore the needle is pegged making it look like the gas tank is at max full.
Sorry to make this so long, but hopefully others will be able to benefit by not having to do all the work I did. Feel free to pass on the photos and any descriptions here. If someone wants to post any of this on the internet that would be excellent. I just haven't gotten around to it.
It's nice to know when you have a full tank!
1
, Fri, 29 Dec 2006 12:07:10
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