Fuel sender units/fuel leak in boot

paroharo · Post by **paroharo** » Sun May 18, 2008 6:31 pm

Hi everyone,

I have a question regarding fuel sender units.
I have looked at these topics already.

http://www.fbekholden.com/forum/viewtopic.php?t=2223 "petrol fumes"

http://www.fbekholden.com/forum/viewtopic.php?t=3106 "Fuel tank sender units"

My problem is similar to the one in the first link, and I have had fuel leak into the boot and it was the cause of my boot mat being eaten away.
When I look at my fuel tank from the boot, (I have pulled up all the layers of matting & there is nothing else but flat sheetmetal on the rest of the top of the tank) all I see is this:

I cant reconcile this to the pic I got from Stingray's post (the second link above) of his fuel sender.

I realise his is a wagon and so is different, but I've seen a sedan one in another pic. Nowhere on my car can I see a plate with 5 holes that would require a gasket..
I believe the fuel is leaking from here

Can anyone shed any light by relating to the picture of Stingray's out of the car as to how the fuel sender is actually mounted in the fuel tank?
I can't work it out

Is this the usual place (red arrow in my pic) that they leak from?
My fuel gauge doesn't work and I can't fill the tank up because it leaks into the boot, so I have to guess how much I've used and fill up 15 litres (approx. half a tank) at a time

Thanks for looking

Trev · Post by **Trev** » Sun May 18, 2008 6:36 pm

The plate is under that cover, just pop the cover off and you will find it, Trev

MINT62 · Post by **MINT62** » Sun May 18, 2008 6:45 pm

Bingo!

paroharo · Post by **paroharo** » Sun May 18, 2008 7:08 pm

I scraped the rust away with a screwdriver & tried that but maybe I need to try harder.

MINT62 · Post by **MINT62** » Sun May 18, 2008 7:48 pm

if you get any crap in the tank you may want to flush it, to avoid problems down the track
id rip that boot mat etc out & freshen things up a bit in there

also i found if you put a small bead of silicone around where the tank meets the underbody, youll stop the water getting in once & for all
do it right the first time if possible

cheers ray

rosco · Post by **rosco** » Mon May 19, 2008 11:14 am

Hi Paroharo,
as mentioned - it's under that cover-
Get your vacuum cleaner out and clean up all the crud under that cover once you get it off............ once you remove the unit anything in that round recess will fall in............ and look out for Bogong Moths (sorry- a short story I wrote some years back when I spent a week trying to get one out of my tank whilst doing the same job).......

There is only a cork gasket which seals the unit in place. I would suggest using some Permatex gasket goo to seal both sides of that gasket - it will certainly be hard to remove later - but how often are you going to replace a unit................... and cork will crumble if really leaned on.

You may wish to use a thin flat piece of wood to lever something on rather than dent your tank when you try to lift the cover.
Also - spray some RP-7/WD-40 or the like around the cover well before trying to prise it up - it will take quite a bit of force to get it out - they are usually quite firmly fitted - even when clean and free of rust.

let us know how you get on..............

frats,
Rosco

(AUST)Mod · Post by **(AUST)Mod** » Mon May 19, 2008 11:23 am

Speaking of things falling into tanks, my sister's EK has an entire plastic fuel filling spout in the tank which my Mum dropped in

paroharo · Post by **paroharo** » Mon May 19, 2008 12:00 pm

thanks for all the info & advice guys, it's a lot clearer now.
it may be a couple of weeks til I get round to it but I'll keep you posted.

cheers,
Jon

Post by **reidy** » Sat Jun 14, 2008 4:31 pm

Be very careful when using vacuum cleaners around fuel tanks!!!!!
Petrol fumes can be sucked into vacuum cleaners with explosive results. An old bloke told me that years ago, he was attempting to remove sand from around the filler neck on one of his cars, and well you know the end result, kah-boom!!!
Bill

rosco · Post by **rosco** » Sat Jun 14, 2008 8:54 pm

Yes Reidy, thanks for cleaning that up - forgot to mention - I would recommend completely draining the fuel tank via the drain bolt and leaving the filler cap off to clear any fumes before playing around with the tank gauge unit.............. sad way to end a vacuum cleaners life............... - long hose and leave the machine outside..............

Strangely, a full tank of fuel is safer than a recently emptied one...................

frats,
Rosco

Post by **reidy** » Sat Jun 14, 2008 8:57 pm

How right you are Rosco, liquid fuel doesn't burn, it's the vapours that do, or am i preaching to the converted.
P.S. DON'T try it !!!!!

rosco · Post by **rosco** » Sat Jun 14, 2008 9:49 pm

No Reidy, I would not for one nano-second suggest anyone try to extinguish a lighted match into a container of petrol...............
I have enough concerns with the gauge unit working at 12v DC being in there.
Fortunately, history has shown us this to be extremely safe..................

LPG however is an alternative I am very much comfortable with leaving in other people's vehicles.......................

Much to the displeasure of the movie world, petrol fueled vehicles are not prone to "exploding" when inverted during or after crash (I refuse to call most of them "accidents" - they are caused).
I have witnessed leaking fuel connections to carburettors actually "dripping" onto hot exhaust manifolds - and quite recently................ to me, this gives every indication that simply inverting a vehicle and possibly having fuel (somehow) flowing onto virgin earth/bitumen gives no cause for an impending explosion............ batteries, dislodged cables and a multitude of other "componentry" afford much more opportunity for this than fuel on earth.

Another little gem we have recently come to learn is that of static electricity................. I feel most are (or should be) aware of the potential for the escaping vapour from the fuel tank filler whilst re-fuelling is a very realistic and devastating likelihood off occurring due to static electricity built up in the human body when re-fueling........... please make sure you "touch" the metal body of your car before filling.

sorry folk, fingers have connected with brain and this momentary insanity has produced the above.......................

frats,
Rosco

Post by **reidy** » Sat Jun 14, 2008 10:03 pm

Don't fret none Rosco, and can i expect you to ragail me with one of your talks about your knowledge of that new fangled discovery "lectricity" after making this statement, but, as you are no doubt aware that the fuel gauge sender unit relies on 12v negative. Come on, i can feel another lecture comming on.
As for LPG, it is relativley safe and i too had reservations about it all those years ago, but there are a few safety devices fitted to vehicles and short of doing something stupid, like taking to a tank with a blow torch, i wouldn't be too concered.
I know it's a different gas. but, how long have we been running BBQ's with the bottle within close proximity to an open flame???
I know, it's hard to protect some people from their own stupidity!!!
But some of us were taught to be cautious !!!

rosco · Post by **rosco** » Sat Jun 14, 2008 10:17 pm

Under a great threat, Reidy - I was taught to be cautious - possibly by the same like-minded elders you were................

Yes I am aware that the 12v sender unit is the negative contact for the circuit but................ I also note, you can get a spark from connecting the negative lead to your battery when the positive is currently connected - guess this conversation/debate is gaining momentum................?

Gas bar-b-que's............. hmmmmmmmm........ don't hear of it often, but when it happens we see the media like to profess the dangers of operating such apparatus.................... as for stupidity, it seems to be on the increase............ everything now has to be "labeled" so you don't create a premature departure from this life and seek position in the next.............

I am not in a position to instruct, but we should attempt to perhaps halve the words we speak in the hope that others may benefit from the process.............

frats,
Rosco

autobilly · Post by **autobilly** » Tue Sep 09, 2008 10:26 am

When you get the cover off and clean everything up to do the job, you could try try a smear of Permatex Aviation sealant on both sides of the gasket. Works a treat for me.
P.S. Make sure there's no rust or filth on the screw threads as that's the ground for the sender.