unit removed from the fuel tank. Using an ohmmeter, check the resistance of the sending unit with the float arm completely down (tank empty) and with the arm up (tank full) (see illustration). The resistance should change steadily from 62 ohms to approximately 2.0 ohms.


9 Remove the fuel pump/fuel level sending unit assembly from the fuel tank (see Section 3).

10 Carefully angle the sending unit out of the opening without damaging the fuel level float located at the bottom of the assembly (see illustration 3.7). Note: On Bosch units, the sender unclips from the container inside the tank - see Section 2.

11 Disconnect the electrical connectors from the sending unit.

12 Remove the screw from the side of the sending unit bracket and separate the sending unit from the assembly.

13 Refitting is the reverse of removal.

5 Fuel pipes and fittings

- inspection and renewal

Warning: Petrol is extremely flammable, so take extra precautions when you work on any part of the fuel system. Don't smoke or allow open flames or bare light bulbs near the work area, and don't work in a garage where a natural gas-type appliance (such as a water heater or a clothes dryer) with a pilot light is present. Since petrol is carcinogenic, wear latex gloves when there's a possibility of being exposed to fuel, and, if you spill any fuel on your skin, rinse it off immediately with soap and water. Mop-up any spills immediately and do not store fuel-soaked rags where they could ignite. The fuel system is under constant pressure, so, if any fuel pipes are to be disconnected, the fuel pressure in the system must be relieved first. When you perform any kind of work on the fuel system, wear safety glasses and have a Class B type fire extinguisher on hand.


1 Once in a while, you will have to raise the vehicle to service or renew some component (an exhaust pipe mounting, for example). Whenever you work under the vehicle, always inspect fuel pipes and all fittings and connections for damage or deterioration.

2 Check all hoses and pipes for cracks, kinks, deformation or obstructions.

3 Make sure all hoses and pipe clips attach their associated hoses or pipes securely to the underside of the vehicle.

4 Verify all hose clamps attaching rubber hoses to metal fuel pipes or pipes are snug enough to assure a tight fit between the hoses and pipes.

5.6 When attaching a section of rubber hose to a metal fuel line, be sure to overlap the hose as shown


5 If you must renew any damaged sections, use original equipment hoses or pipes constructed from exactly the same material as the section you are renewing. Do not install substitutes constructed from inferior or inappropriate material or you could cause a fuel leak or a fire.

6 Always, before detaching or disassembling any part of the fuel line system, note the routing of all hoses and pipes and the orientation of all clamps and clips to ensure that new sections are installed in exactly the same manner. When attaching hoses to metal pipes, overlap them as shown (see illustration).

7 Before detaching any part of the fuel system, be sure to relieve the fuel line and tank pressure by removing the fuel tank cap and disconnecting the battery (see Chapter 5A). Cover the fitting being disconnected with a rag to absorb any fuel that may spray out.

removal and refitting

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