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Thread: Fuel Sender

  1. #1
    Senior Member mrbigport's Avatar
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    Craig
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    Hey, for the majority of sprinter owners that gauges play around.
    And lack of guides with pictures. I decided to make one for those
    people that thought it was too much of a hassle. It will take about
    5-10 minutes depending on the garbage you have in your boot

    You will need:
    Philips head screw driver
    Small flat head screw driver
    A rag
    A celebration beer

    Caution, if you have brass tools or whatever please use them, a spark
    made can cause some unpleasantries when working with the sender.

    Remove all the junk from you boot especially anything that can cause a spark then locate the sender unit in your boot. It will be under on the drivers side near the spare tire. It will have 3 screws and 2 looms(one with 2 wires and one with 3 wires). You may want to remove these plugs to work with the sender a bit easier

    [attachment=8557:attachment]

    Underneath this is the actual sending unit. Undo the 6 screws at the top and remove the sending unit. You might want to rub around the area with a cloth so you dont get much crap into your tank

    [attachment=8558:attachment]


    You will see a metallic rectangular box with two arms coming out. One with a wire around it that sends the empty fuel light to turn on and another arm with a floating device (black box thingo).

    [attachment=8559:attachment]

    One the actual unit there are three tabs. lift these up with a flat head or preferably your nails if you can. slide out the box. (tabs are circled)

    [attachment=8560:attachment]

    You should see this inside. bend the sending thingo so that it makes contact with the coil throuhout the entire travel. You can reattach the plugs at this time if you desire and move the float around and watch the fuel gauge to be sure its working

    [attachment=8561:attachment]

    once everything is all good. reattach the cover and work backwards to reinstall the sender. Congrats you now have a decent sender (unless your float doesnt work or some electrical problem but then thats not my problem =)
    4agte KE70 263.6whp

    QR Sprint Circuit 1:02.9
    QR Sprint Circuit 60.7 (turbo)
    QR Clubman Circuit 1:06.41 (first outing NA)
    QR Clubman Circuit 1:02.77 (turbo)

    http://www.ae86drivingclub.com.au/fo...ustom-Stickers
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  2. #2
    Veteran Bustin_86's Avatar
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    Justin
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    Thats an awesome guide, need to do this to my car.

    Cheers mate!

  3. #3
    Senior Member Beserker99's Avatar
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    Phirom
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    Ahhhh, fkn hell. I tried doing this to my car liek a week ago, but I didnt know ya ahd to take the tabbed cover off. I though it was just the wire that touches the long sender

    Oh well, back to doing that tomoz then

    Cheers for the tute!!!!

  4. #4
    Senior Member Dori_Dori's Avatar
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    Andy
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    great write up man
    good advice to all the ae86 lovers in need of some DIY
    help/fuel sender.....
    ""A celebration beer"" for sure YO

    Cheers

  5. #5
    Senior Member HYPNTK's Avatar
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    hey man just saw this and i've had to rely on my light to come on to top-up juice all this time! only a couple of days ago that failed too and almost left me stranded (lucky there was a servo at the bottom of the hill i was rolling down )
    mechanics just tell you to replace stuff till you fix the problem whereis this is awsome mate, thanks a lot

  6. #6
    Senior Member HYPNTK's Avatar
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    hey i just tried doing that now and when i was moving the metal thingo side to side on the copper thing my fuel gauge wouldn't move and then when i put it all together my gauge was still stuck on empty...(mind you my tank was almost empty)

    went for a drive, put $20 juice in it and the fuel gauge came up almost to half way...seems this method has worked but is the reading correct? i only ask because it says on here that when you move the metal thing along the copper thing your gauge should move too...meh! at least its not stuck on empty any more hehehe

  7. #7
    Senior Member mrbigport's Avatar
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    Doesnt that sound about right? nearly empty when doing the sender.. putting 20 bux of juice, which equates to roughly 15-17 Litres depending on the price of petrol..

    so 15-17 is a bit less then half the 40L tank of the ae86.. so doesnt the sender sound like its giving a correct reading at almost half (well half decnet reading)

    the gauge moves when u move the contact about the coil.. u just need good eyesight to see it from the boot.. or leave it at full somehow and sit in the cabin.. should see the sender moving to double check it works.. (also make sure the 2 plugs are reconnected when testing )
    4agte KE70 263.6whp

    QR Sprint Circuit 1:02.9
    QR Sprint Circuit 60.7 (turbo)
    QR Clubman Circuit 1:06.41 (first outing NA)
    QR Clubman Circuit 1:02.77 (turbo)

    http://www.ae86drivingclub.com.au/fo...ustom-Stickers
    full colour windscreen banners from $45!

  8. #8
    Senior Member HYPNTK's Avatar
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    oh ok nah i was wearing my specs when i was trying this and it wouldn't move..got someone to do it for me too while i sat inside and didn't move so i was a bit dissapointed but then when i put juice in it its been working ever since so it doesn't matter now anyways...

    i wonder why it stuffs up in the first place...can metal "un-bend" itself over 20 odd years???

  9. #9
    Oldschool Member
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    Fuel senders can still be ordered from toyota. I know there were a few different part numbers based on what year/month your car was produced.

    My car is an 86 model year produced in 10 of 85 and the part number for my fuel sender was 83320-80039 This part should work on any AE85/86 made after 10 of 85


  10. #10
    Senior Member mrbigport's Avatar
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    Craig
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    yup they can still be ordered i got quoted $225 + Gst and 3 weeks until it came from japan..
    4agte KE70 263.6whp

    QR Sprint Circuit 1:02.9
    QR Sprint Circuit 60.7 (turbo)
    QR Clubman Circuit 1:06.41 (first outing NA)
    QR Clubman Circuit 1:02.77 (turbo)

    http://www.ae86drivingclub.com.au/fo...ustom-Stickers
    full colour windscreen banners from $45!

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