Fuel Gauge Fault? Replacing a fuel tank sender - Fiat Ducato, Peugeot Boxer, Citroen Relay etc.

[@vincechittenden]

Excellent video! Thanks for posting. My fuel gauge has suddenly started taking ages to respond to a re-fuel. I filled the tank and the gauge initially read empty (inc warning light) but as I drove the van, it gradually crept up to near full, over a period of 15 mins or so. So now I'm not sure I can trust it. The garage just told me that it's "a tank out job" to change the float. Your video seems to prove otherwise! Mine is a 2004 2.3TD Ducato, so I'm hoping is the same procedure as you have shown, should I eventually have to change it. Cheers

[@bobflyman]

Best way to find out is to look under the front mat! Tank out? That's what I was worried about. I dropped the tank in my old VW T25 Transporter, it wasn't an easy job! Best of luck mate.😉

[@davemaddison782]

Thank you for the video. It saved me loads of time as I prepared beforehand; clipped the excess off the soldered joints. . Also, I trapped and broke a wire when refitting - stupid design - re-soldered and bent the three wire connectors to avoid shorting. Just a tip: I found feeding in the new unit easier by unclipping the float, pop them both through the hole then reassembling with the unit and float partly inside the tank. 1997 Fiat Pilote Camping Car.

[@bobflyman]

Great, well done. Float was the problem for sure, don't think mine could be removed though. 😥

[@wsherratt5159]

Thanks Bob, If you look up the word persistence in the dictionary, you’ll find a direct link to this video! I really liked the fact you kept at it and filmed it all the way through. It gives those of us facing the same issue a little bit of confidence to give it a go mate. W

[@bobflyman]

Haha, thanks, you made me laugh! 😊 He who dares wins, and don't give up, you'll get there in the end 😊

[@wsherratt5159]

@@bobflyman Cheers matey. I’m about to go in. I’m following your advice and cleaning up the connector first. 🤞🏻 that’ll work. Beats me how you didn’t swear! +§@€%”;!

[@willismorgan8369]

Hi Bob thanks for showing this video with all the problems of how to change a fuel gauge very good many thanks willemog.

[@bobflyman]

Glad you found it useful mate!

[@brightgreencarrot]

Thanks for the video, it saved me a lot of time and grief sorting out the fuel tank on my 92 Ducato. 👍

[@bobflyman]

I'm glad it helped mate! I've updated a bit a few months ago, 2016 Renault Trafic 1.6 CDi 30k miles on the clock, which I fitted out as a small camper. Lots less space but very different to drive! I have to watch the speedo as it creeps up 80, 85 ... air conditioning, smooth, quiet. Even fitted a Chinese diesel heater! kzbin.info/www/bejne/nImvYqGBhd-Mbs0

[@CliffHarveyRCPlanes]

Excellent video Bob, glad I'll never need to do this job 👍

[@bobflyman]

You might have to one day! 😉

[@MrSamcab21]

Ive got a 51 reg ducato. And mine is playing up. So im about to change mine, thanks for sharing this, very informative..

[@bobflyman]

Glad it was useful mate!

[@Ballindud]

Thanks- think i have same problem. Fuel gauge pointer all over the scale. I have a Hymer B754 on a Fiat Ducato 2001 chassis. The fuel pump and sending unit looks similar to your setup.

[@bobflyman]

Glad it helped. Have a go, if you can find the part you may be able to fix it! Good luck.

[@charleyparley]

great video thank you for posting it, i was going to do the same on my 1999 ducato motorhome, but after watching your video i will probably just keep filling up every 150 miles

[@bobflyman]

Ha ha, might be easier! It wasn't so bad, the hard part is finding the right part. It was a bit of a gamble and I'm pleased it's working now.

[@bobflyman]

Try replacing the spring on the clutch pedal, assuming you have a cable clutch? That was a pig of a job. Plastic pedal broke so had to replace pedal and spring. Quite a common problem apparently.

[@bobflyman]

I carry a spare pedal now.

[@TheDELAMY]

Great Video Bob.On your Ducato (2001) do you have an Engine Compartment Fuse Box- or a Fuse box containing Fuel Pump Relay & Fuses.

[@bobflyman]

Hi mate, it's a Peugeot Boxer Autosleeper Pescara version 2001. It has a fuse compartment in the passenger glove box. I just found an online diagram which shows 3 different fuse boxes. Confusing! Mine doesn't have a fuse box under the bonnet, or if there is I can't see it?

[@covinhas87]

This was entertaining 😄 My fuel gauge is showing zero, doesn't move at all.

[@bobflyman]

Zero isn't great! That must be slightly worrying 😳. See if you can pull out the sender, though it might be the gauge at fault. It'd be an idea to find a way to check that and check connections to the sender. If you short the 2 wires to the gauge it should, or maybe will, show full? Good luck!

[@stevenward5959]

Hi bob great video am going two try do this same job two moro i have found one but its a 19td diesel 2001 my one is a 2ltr petrol 1996 hop the sender unit is the same do you know if it will be the same thanks

[@bobflyman]

Hi mate, sorry don't know the answer to your question, but if you take it step by step hopefully you'll sort it out!

[@ralki30]

Great video bob, where did you purchase the new unit from please.

[@bobflyman]

Sorry mate, I've looked right back through my Paypal account and can't find where I got it from. I just went online and Googled the part. The float on the one I got was different to the one I took out and I just Googled again and saw one with the same float, probably would have been better. Just try and find one with the same float and same plug connection.

[@bobflyman]

Here are two different ones. Cylindrical float. www.ebay.co.uk/itm/133255285251?var=0&mkevt=1&mkcid=1&mkrid=710-53481-19255-0&campid=5338343596&toolid=10001&customid=eb%3Ag%3Avms%3Aeb%3Ap%3A133255285251%3BCj0KCQjwxb2XBhDBARIsAOjDZ34OWNmHRz0Hh1FEZJHXcK-hx4CUTwEE5dhjhSCQ8psuz9CHzbWGbWsaAiLkEALw_wcB&gclid=Cj0KCQjwxb2XBhDBARIsAOjDZ34OWNmHRz0Hh1FEZJHXcK-hx4CUTwEE5dhjhSCQ8psuz9CHzbWGbWsaAiLkEALw_wcB and round float www.ebay.co.uk/itm/154995199603?fits=Car+Make%3AFiat%7CModel%3ADucato&hash=item24166f0e73:g:F~EAAOSw8TJigL~R

[@Anonymous.1984]

Hi there as I type this I'm trying to repair my citroen relay 230 2.0l petrol sender unit. I've tested it and it's definitely the sender unit. Can't get a replacement from anywhere as the fitting is different to yours and mine has an inbuilt pump. I just need a new float arm and resistance control board (bit with 2 wires) do you know if the sender unit you've put in is a 2 wire or 3 wire resistance unit? If it's 2 wire I'll be able to order one and just swap the board and float over if not I'm screwed

[@bobflyman]

Wow, that's a difficult question and I don't have the vehicle anymore . (Bought myself a 2016 Renault Trafic and fitted it out. It's a joy to drive!) Unfortunately I chucked out the old unit recently (I'm a hoarder of things that might come in useful. 😩) pretty sure it had 3 connections. Can you not see the wires if you zoom in? I'm abroad at the minute so can't really check the video. That part of the thing is very simple, you've got the resistive wire and a slider that slides up and down. Like a potentiometer. Most pots need 3 wires. But you could have a circuit where there is a voltage there and two wires and it just sends a variable voltage. You probably know that. Can't you repair the sender part? Put a meter on volts and try ohms and see what changes. I found my replacement with a bit of googling, wasn't totally confident it was right or would work, but it did. The float was bigger and a bit of struggle to get in but thankfully all worked afterwards. Good luck with sorting it!

[@Anonymous.1984]

@@bobflyman yes I've tested my sender unit. And at empty it sits around 300 ohms then as soon as I move it to quarter it goes open circuit and reads nothing above that so it's definitely the resistance board that has gone faulty. I'm trying to see if a sender for a diesel would have the same resistance range and if so I'll just buy one of them and rob the parts I need off it and fit to mine

[@silvestrerodriguez2246]

En ducato 230 ese problema no es el aforador ni el cuadro de intrumentos. El problema es en el módulo. Saludos

[@bobflyman]

gracias.

[@peterhalls7609]

Thank you, that was very helpful. But I'm not looking forward to what lays ahead.

[@bobflyman]

Job isn't too bad as long as you can find the right one with a float that will go into the hole!

[@abkxx]

You could also clean the old one with wd40 and on again

[@bobflyman]

I tested with a meter, it was dead!