My Fuel System Hates Me...

So in my quest to solve my no spark/no fuel issue I replaced the fuel pump. Well, it turns out it wasn't the pump. But, while putting the sending unit back in I must have inadvertently damaged the resistor that measures the tank level as the needle jumps all over the place now. It settled on 1/2 full and I have about 3/4 in the tank.

So I need to drop the tank AGAIN (3rd time's a charm right?), swap out the sending unit. May even go and put that Delco pump in too. I'm also going to do what Dave suggested and use the high pressure hose to safeguard against a blown hose. What size hose should I get that is as close to stock size as possible?

Hope all the info on your wagon applys to my 91OCC because I want to replace all of that stuff
shortly.Only has 71000 miles but all that stuff is original and 20 years old.Thanks ahead of time
hopefully for all the information.
Jim

Cadet57: The float arm may have just slipped out of its clip, or the clip may be cracked. Check the hose size on the new pump. Use a hose that is good submerged in gas. One that is alcohol resistant would be advisable too, because the fuel has alcohol in it. For the most part, the alcohol is what deteriorates the hose.

Flash: you probably do not have to replace the parts in your tank, The hose between the pump and the outlet tube is the only part that deteriorates appreciably, and should be replaced. If the gauge works normally, you should not mess with it. I would run it until it actually has a problem. The symptoms have been discussed ad nausium here, and you should be able to diagnose any issues that appear.

You can tweak the little copper sweep arm that touches the resistor to increase the pressure and make better contact. First, I used fine girt emery cloth( 1000 grit or higher) on both to remove the corrosion before re-assembly, As an afterthought, a pencil eraser would have worked as well.

It helped. You can dial it in after ward with a resistor from Radio shack if necessary. there's a few threads about that around here.


Dave

Fred Kiehl wrote:

Cadet57: The float arm may have just slipped out of its clip, or the clip may be cracked. Check the hose size on the new pump. Use a hose that is good submerged in gas.

No kidding. That's why I asked WHAT SIZE. I could have figured out holding it up to the pump....

lakeffect wrote:

You can tweak the little copper sweep arm that touches the resistor to increase the pressure and make better contact. First, I used fine girt emery cloth( 1000 grit or higher) on both to remove the corrosion before re-assembly, As an afterthought, a pencil eraser would have worked as well.

It helped. You can dial it in after ward with a resistor from Radio shack if necessary. there's a few threads about that around here.

I can't solder to save my life. And this sending unit is still under warranty so i'd rather just put in a new one instead of me trying to fix it.

Heres something that may be handy

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1phastsswagon wrote:

Heres something that may be handy

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.... I know HOW to refurbish it. I just can't solder and as i've said 2x now the broken one is under warranty. Hence, free to replace.

WOW - Ok didnt see your post previous to me posting mine - my bad

Chill Justin everyone is trying to help you here.You're young and frustrated with your wagon which
is understandable,I would be pissed too.Dont take out your frustration on those trying to help
you.Now BEHAVE and play nice!
Jim

Flasheroo wrote:

Chill Justin everyone is trying to help you here.You're young and frustrated with your wagon which
is understandable,I would be pissed too.Dont take out your frustration on those trying to help
you.Now BEHAVE and play nice!
Jim

I'm fine. I just hate posts that give me the same info I already know. And I have to repeat myself multiple times. Or just read like someone never actually read the first post. Or post things that don't help at all like "buy a size that matches the fuel pump" Like I could have never guessed that on my own.

Wait about 30 years and see how often you repeat yourself!
Wait ab nevermind
Jim

Flasheroo wrote:

Wait about 30 years and see how often you repeat yourself!
Wait ab nevermind
Jim

What were we talking about now?

Don't upgrade the hose - just leave what's in there.

On a side note, it's interesting to see that someone swiped all of my photos and text, rewrote it with misspellings and then posted it unattributed. Swell guy.

WAIT,I know it was about an instrument cluster and nevermind!
Jim

sherlock9c1 wrote:

Don't upgrade the hose - just leave what's in there.

The stock hose is good you think then? Cool. One less thing to worry about.

I don't get all the drama about dropping the tank. It's not that big of a deal, especially if you've already just done it recently.

Bewber wrote:

I don't get all the drama about dropping the tank. It's not that big of a deal, especially if you've already just done it recently.

You're right, its not a big deal. Its only 4 bolts. I just get lucky every time and have a full tank of gas every. single. time. And I can never siphon more than 6-8 gallons out. I fail at the fuel tank game.

Wow you suck at sodering and siphoning!I think there may be something wrong with your mouth/
lips or something like that!
Jim

Flasheroo wrote:

Wow you suck at sodering and siphoning!I think there may be something wrong with your mouth/
lips or something like that!
Jim

I blame the cheapy $3.99 hand pump I got at harbor freight. As for soldering, I've never been able to master it without managing to burn some part of my body or dripping melted solder everywhere.

You obviously did not take note of my post, and I hate to repeat myself too. The float arm may have slipped out of the clip that holds it. There may be nothing wrong with your sender. Look at it before you take it back, it could be a simple fix. It is easy to knock the float arm out of the clip when installing the unit.

Like I tell everyone who has to drop their tank, while it's out, spend $4.00 to put a transmission pan /oil pan drain plug in it. Hopefully, you'll never have to pull it again, but if you do, then it won't matter if it's full, as it can be drained.

Best of all... no soldering.

Personally , for what little fuel line hose will run, put in a new fuel resistant piece that is reinforced. About one foot curled in a loop is all you need. That thin hose that is supplied bursts very easily. Been in my tank three times within weeks of each event.

I also used the metal screw on clamps, like tiny radiator clamps. I've had bad luck with those little plastic crimp on clamps.

Dave

Justin there is nothing hard about sodering as long as you follow the "Golden Rule".Never,under
any circumstance no matter what ever soder NAKED!
Jim