Electrical: In Tank Fuel Pump Electrical Sender Repair??

[Big 240]

Originally Posted by Othen

Have you already done this and it worked? If so well done.

Post some pictures and words in case the repair is useful to someone else please.

Alan

So as stated I have done the fix and it works. It's not the prettiest of fixes as the corrosion on the top part is pretty bad. I will clean this up before I refit, however as a temp solution it is perfect for the job.

I ended up cutting the spare pipe down to about 5mm proud, and filed/deburred the edges so it was smooth. I fed the black and the grey wire down the tube and soldered these (and sleeved them) to the corresponding wires from the pump and the level sender (black to black and grey to the thin blue wire from level sender). I used some heat shrink where the wire goes through, and comes out underneath along with some araldite to hold the wires in place etc.

I cut out the old plastic part that held the connector on top and used the hole that was left as the earth point. I used a new nylock nut and bolt.

I will be replacing with a new unit once funds permit.

[Juular]

That looks like an elegant and well thought out fix. That'll last ages.

[Big 240]

Originally Posted by Juular

That looks like an elegant and well thought out fix. That'll last ages.

As I'm fairly new to this site I'm not sure if this is sarcasm or not... but I don't think it is..... so thank you

[Othen]

Originally Posted by Big 240

So as stated I have done the fix and it works. It's not the prettiest of fixes as the corrosion on the top part is pretty bad. I will clean this up before I refit, however as a temp solution it is perfect for the job.

I ended up cutting the spare pipe down to about 5mm proud, and filed/deburred the edges so it was smooth. I fed the black and the grey wire down the tube and soldered these (and sleeved them) to the corresponding wires from the pump and the level sender (black to black and grey to the thin blue wire from level sender). I used some heat shrink where the wire goes through, and comes out underneath along with some araldite to hold the wires in place etc.

I cut out the old plastic part that held the connector on top and used the hole that was left as the earth point. I used a new nylock nut and bolt.

I will be replacing with a new unit once funds permit.

Excellent, well done - and that is a really good 'how to' post should anyone else need it.

Why would you waste money on a replacement if it works? It looks to me like it will last the life of the motor car.

Alan

[Othen]

Originally Posted by Big 240

As I'm fairly new to this site I'm not sure if this is sarcasm or not... but I don't think it is..... so thank you

Certainly not! Juular is a very well respected correspondent; he has produced some excellent low cost fixes (have a look at his 240 and Amazon project threads, they are a really good read).

https://www.volvoforums.org.uk/showthread.php?t=312429

https://www.volvoforums.org.uk/showthread.php?t=324503

Alan

[Big 240]

Originally Posted by Othen

Certainly not! Juular is a very well respected correspondent; he has produced some excellent low cost fixes (have a look at his 240 and Amazon project threads, they are a really good read).

https://www.volvoforums.org.uk/showthread.php?t=312429

Alan

I certainly will take a look thanks.

I was only checking as I have come across from the world of VW's (been driving them since I was a kid Beetles. Type 3's etc) and it's a slightly different world on the VW forums. Not too dissimilar, so I'm still seeing what counts as banter on here

I have made many How-To guides on the UKPassat forum and I intended to do the same for this one as I took plenty of pics when I replaced the pump too. I want to get it cleaned up a little first then I'll post the How-To etc.

[Othen]

Originally Posted by Big 240

I certainly will take a look thanks.

I was only checking as I have come across from the world of VW's (been driving them since I was a kid Beetles. Type 3's etc) and it's a slightly different world on the VW forums. Not too dissimilar, so I'm still seeing what counts as banter on here

I have made many How-To guides on the UKPassat forum and I intended to do the same for this one as I took plenty of pics when I replaced the pump too. I want to get it cleaned up a little first then I'll post the How-To etc.

Good. I think everyone in the 200 section is pretty sincere and genuine.

We like 'how to' guides and project threads a lot.

:-)

[Steve 940]

Originally Posted by Big 240

I certainly will take a look thanks.

I was only checking as I have come across from the world of VW's (been driving them since I was a kid Beetles. Type 3's etc) and it's a slightly different world on the VW forums. Not too dissimilar, so I'm still seeing what counts as banter on here

I have made many How-To guides on the UKPassat forum and I intended to do the same for this one as I took plenty of pics when I replaced the pump too. I want to get it cleaned up a little first then I'll post the How-To etc.

Hi Big240,

As an ex owner of 2006 Audi A6 Allroad, and VW Audi forum user, I joined around a year or so ago on purchasing a '94 940 Estate.

I can definitely confirm that based on my experience on here, virtually all contributors are helpful and courteous, and occasionally posts may also be humorous. I certainly came across some threads on the VW/Audi forum where posts were just downright rude/abusive.

Othen (aka Alan) is being far to modest to suggest looking at some of his own threads, but some excellent ones on various 204 projects. Also agree Juular has some excellent threads on his projects.

Cheers
Steve

[Juular]

Originally Posted by Big 240

As I'm fairly new to this site I'm not sure if this is sarcasm or not... but I don't think it is..... so thank you

Not sarcasm at all. Nicely done!

[Big 240]

Originally Posted by Juular

Not sarcasm at all. Nicely done!

Cheers man, I will be cleaning up the top and using some rust inhibitor to try and stop the rot. I have always enjoyed thinking laterally when problem solving it can save much money haha