Digital Dash Fuel Sender Fix

Tools needed: Phillips screwdriver, small flathead screwdriver, a pair of pliers (or two pairs) a small spring washer (bout 2mm thick with an inside diameter similar to the floater)

Step 1

Open your boot and lift the carpet on the drivers side
You will find a odd shaped circular plate with 3 screws in it
Remove the 3 screws and underneath you will find the fuel sender

Step 2

Unplug the 4 pin plug which is going to the sender, then undo the 5 screws in the sender itself, slowly pull the sender and wiggle it slightly to get the casing out of the tank

Step 3

Once you have the sender out of the fuel tank you will see the steel casing (looks like a square) with the floater coming out of it
You need to bend back the 3 tabs that hold the casing on

Step 4

Once you have that off you will now see what the problem is… the part I have circled in the picture if you have a look at it, you will see there is a spring located below the circular plate, this plate happens to move in and out, therefore causing a loss of contact for the fuel sender. This part is connected to the floater, when it is working normally a little steel plate comes off that section and runs along the area I have coloured in blue, with this having such large movement the plate comes away from that section and has no contact, hence the dash showing you a fault with your sending unit

Step 5

You need to get a spring washer and open it up so that you can place it on the brass coloured washer that is already on the sender, if you have a look at the floater and follow it back up to the casing you will see that it has a slight bulge, the washer needs to be placed under this against the brass coloured one so that it stops the movement.

You can allow for slight movement of a few mm but I would suggest not more than that
You should notice that the little steel slider now does not lose contact with the fuel sender

Before you reassemble the sender, plug it back into your plug in the boot and turn your ignition on just to try it, if no more flashing then you were successful
Reverse steps 1-3 for reassembly and place it back in.
Don’t worry about which way the sender was when you pulled it out as the holes will only line up one way, if in doubt you can just check the images above for correct placement