How To: Correctly Fit a Fuel Tank Sender Unit

Cambiare provides technical insights on how to correctly conduct the installation of Fuel Tank Sender Units & the problems caused by incorrect fitment.

The Situation

Vehicle manufacturers are increasingly trying to reduce the weight of vehicles and maximise under vehicle space. As a result, fuel tanks can come in a variety of shapes and sizes. They contain ledges, corners and in some cases even have baffles (found in the fuel tank and used to slow down or divert the flow of gases, liquids and sound) and regulators. For this reason, correct fitment and location of in-tank fuel units during replacement is imperative for accurate fuel level indication.

Incorrect Fitment

If the tank units are not fitted correctly, the float arm can get caught on a ledge in the tank or trapped against an internal component, which in turn can cause an incorrect fuel level reading, resulting in the engine stalling due to the vehicle running out of fuel.

Correct Installation

Most in-tank sender units have marked indicators on the top flange cover, which should be lined up to markings on the fuel tank itself to ensure correct location of sender units and correct operation. Alignment of these indicators should be checked after securing the lock ring to ensure no movement has occurred. The use of correct tools will assist this.

When carrying out fuel tank sender unit replacements, be sure to have these markings in line to avoid customer breakdowns and possible false warranty claims.


Click below for a PDF copy of Fuel Tank Sender Unit fitment from Cambiare Tips & Tricks.


Check out other sections of the Vital News blog.