can i use a resistor to calibrate fuel sender

(genius at work here), Site Problems, Suggestions, and Questions. Of course you could easily recalibrate the gauge to reflect actual fuel levels by repainting the marks on the gauge face. I did a column on fuel gauge sender unit repair; if you can't find a reference in the FAQ archive, drop me a PM and I'll send you the column. Cies Fuel Sender System . S = This connects to the sending unit in the fuel tank. Your previous content has been restored. Conveniently (or not) the sender works the wrong way around compared to all aftermarket gauges and senders. They can be cleaned (VERY carefully) with carburetor cleaner and a Q tip. 0 �8�Y H�\��n�0��@�I�@Y��?Ց)�C��>�v��l�qla6�~�b��s�~��t};^-��ܯs��Әյ��9��æ��1��.�~8��?�ã��i��0̦0��) }k��%�|Y��~�?�5��}��aڱשiCl�s��"kS��c��S. What size wire do I need to use for the instrument cluster installation? As the fuel arm moves from the empty to the full position a contact is moved across the board on the rheostat which varies the resistance seen by the fuel gauge. The calibration ought not to change, but you never know. It seems like the traditional solution for the fuel sender in a 12 volt upgrade is to simply put a resistor in the line, but the theory kind 'scapes me. 20 AWG is sufficient for most wiring. trailer I took a few (terrible quality) pictures of the fuel gauge in my '74 as a function of sender resistance. 0000002539 00000 n I'm not cancelling the order, just because California pissed me off... good to have a spare before they start scanning packages too. Testing can be done by removing the sending wire from the gas tank sending unit and plugging in the test unit. Make sure the brown ground wire on the sender is clean and making a good ground (in addition to checking the ground on the instrument pod). endstream endobj 56 0 obj <>/Metadata 15 0 R/Outlines 6 0 R/PageLayout/OneColumn/Pages 14 0 R/StructTreeRoot 17 0 R/Type/Catalog>> endobj 57 0 obj <>/ExtGState<>/Font<>/XObject<>>>/Rotate 0/StructParents 0/Type/Page>> endobj 58 0 obj <> endobj 59 0 obj <> endobj 60 0 obj <> endobj 61 0 obj [/Indexed/DeviceRGB 255 80 0 R] endobj 62 0 obj <> endobj 63 0 obj <> endobj 64 0 obj <>stream ‪Fuel gauge calibration‬‏ - YouTube ... but I can tell you that using a variable resistor or potentiometer is the method for testing gauges and gauge circuits in Ford dealerships for most cars made basically forever up until recently when gauge circuits are becoming digitized. Cavitating pump = loud pump. 0000010103 00000 n Consulting my good ole BMWnospaceCCA Tech Tips book from 1975, the writeup on the 2002 fuel sender shows that with the float at the top of its travel (full tank) an ohmeter placed across the two contacts should read essentially zero ohms, and with the float at the bottom of its travel (empty tank) the ohmeter should read 75 ohms. It is recommended to use a 3 Amp automotive fuse when supplying power to this gauge. Can I put my gauge cluster into DEMO mode, for display at an event, or testing purposes? It's a thin wire that clips on the sending unit and has a portion that inserts in to a tiny hole in the side of the silver cylinder. I really don't know, certainly some BS law that should not apply to a generic part used in a 1973 car which is pre-smog and that I am free to modify. I've observed the same thing on other 2002s over the years, so that's at least a small sample reflecting that behavior. Trying the pump: I had my kid turn the ignition and observed a dribble of inconsistent fuel out of the pump... Hmm, possibly the pump then. If you can get those and post them up here we can select a resistor value and create a calibration curve. 0000008491 00000 n GM fuel sending units are designed to indicate the fuel level using a resistive signal. 0000001116 00000 n The sender consists of a float on an arm that varies the resistance the sender applies to the circuit with gauge. 0000022255 00000 n �CE��B�h+q؇�� 41�Q��~6�:i�H~�v��X�n��=�� ـ�p��Ω8ۙ�~[v�7^E�\��}��A�9D��0�ӳ.�R�[�:w��^AT߼��( EMPTY. Clear editor. Note: Your post will require moderator approval before it will be visible. Testing can be done by removing the sending wire from the gas tank sending unit and plugging in the test unit. I did not clean the wires. I build a cheap testing device using a 0 to 100 ohm potentiometer, then built a small box to house it and marked the exact calibrations for 0, 33 and 78 ohms on the box. With this module, you can use your stock sender with virtually all common analog fuel gauges and vice versa. I used a 1/16 inch diameter welding rod with marks on it so I could physically push the float up inside the sender to 1/4, 1/2, 3/4 and Full positions. **(See Sending Unit Wiring Section) I = Supply 12v, key on power to this terminal. endstream endobj 65 0 obj <> endobj 66 0 obj <>stream It is analogous to the maximum fuel adjustment screw on an old fully mechanical injection pump. I'm sure someone on here knows what the min and max resistance is supposed to be. This will "polish" the wire and remove any debris that could cause the float to stick. The only easy way to accomplish this is to reduce the voltage to the fuel gauge with a small voltage reducer (resistor!). The gauges on both my '69 and '73 take forever (200+ miles on the highway) to get down to perhaps 3/8 of a tank (between half and quarter) then drop precipitously down to the red mark--often in 30-40 miles. I once calibrated the one in an old VW. (Right tail light assembly shares a common ground with the fuel sender). 0000061228 00000 n H�\��n�0��y Display as a link instead, × I re-assembled and it still gives a lopsided reading. 0000060742 00000 n It takes 10v through the voltage stabilizer. To convert a resistance sensor to a voltage, a pull up resistor is required, see figure 1 below I bent the arm down until it just hovered above the bottom of the tank (like by 1/2 a mm). I have put sealant to prevent the gas leak I had, it's a pain to remove all that. There are a couple ways to "calibrate" the MM with and without a sender, but I think the easiest and most accurate is to use the an actual sender and gauge. If that passes muster, time to check the gauge by connecting a known resistor close to the gauge to see if it reads full scale. With this simple device, you can ensure your gauges are accurately reading your fuel level. At half a tank the gauge plummets. GM cars from the 1930s to the 1960s operate on a 30 ohm scale. Out of Calibration Reason 1 The resistance range of the sender unit is wider than what gauge can indicate. These are a tube apparatus with a float in the middle. Very small readings when the tank is full. The 3/4 mark is near the full mark and the 1/4 mark is near the empty mark... so the first 1/4 seems like it lasts forever and the second half of the tank seems like it disappears quickly. Wiring suggestions ? With the float unit way up to full, gauge reads 3/4. I'd start by seeing what the resistance swing is as you make the sender go through full travel. H�\��j�0��z I'm having a hard time believing they'd let that pass. Also connect one of the resistors to ground on the case, and you can leave it connected that way for the duration of this calibration exercise. A 40 Ohm resistor will indicate about 1/2, and a 60 Ohm about 1/4, etc. To correct for this variability, in gasoline applications we use a scheme we call Full Detection where the sender detects a fillup and rescales the calibration if the reading would otherwise be something other than Full due to the percentage ethanol. Perhaps it's sticking part way and not dropping as the fuel level falls away beneath it. It's linear, so at midpoint the reading should be 37.5 ohms, etc. SENDING UNIT The sending unit is installed in the fuel tank and consists of a float and arm that is attached to variable resistor. All the parts are new(ish) but from different vendors. Grab a handful of 10 ohm resistors and connect them to the sender connector that leads to the gauge. I, Fwiw: my car has the smaller 46 liter tank and I have a lead foot (4800 rpm ALL the time on the highway, w a 4 speed and 3.64 rear. ) new sender ? What I done was cut a gm sending unit off a spare sending unit and turned it upside down and used 2 small hose clamps to attach it to the pickup tube and used a 100 ohm resistor to calibrate it to the Toyota gauge I think the gm was 125 full and 20 ohms empty. I vaguely recall many years ago I accidentally reversed the electrical connections to the fuel sender (standard, no fuel pump) and the fuel gauge remained stuck in the 3/4 position. Using five 15 ohm resistors in series, I connected them to the wires that norm, Gently use a jeweler's screwdriver and pop the metal edge off the plastic portion. I tested this outside the tank. I also have retained the stock fuel tank and sender in my 240Z, but wanted to use a matching Autometer Pro-Comp Fuel level gage. available to change the gage readings. Temperature gauge does not read correctly with single wire temperature sender. The sender resistance is shown in … The problem with fuel tank sender units is that they are normally resistive sensors, and AIM products require voltage signals to work. 0000005203 00000 n However! Zero ohms correlates to "empty" and 90 ohms correlates to "full". Today I decided to take a closer look and pulled the inline Mann fuel filter, which immediately shot fuel 6ft in the air (pressurized). Ever notice how long that tube takes to drain when you remove it from the tank? Make sure the brown ground wire on the sender is clean and making a good ground (in addition to checking the ground on the instrument pod). The fuel gauge is composed of two components: a sender in the tank and a gauge on the instrument panel. 0000060483 00000 n Electrically all sensors can either be resistive (eg a temperature sensor) or voltage (a suspension potentiometer). Some tests can be done to get an idea of the accuracy of the gauge. I think part of the problem is that flat tank, and the fact that the sender unit is inside an aluminum tube, which keeps the gauge from jumping all over the place as gas sloshes around in the tank. 0000056701 00000 n 0000005753 00000 n The inner wire(s) are delicate. �%o��W�9�֖��$��\�-ق�,`f��`��`f��`7� ��B/��K�%�x �^B}��x��W�+;��;�:�:�:�:�:�:�:�*�+�+�+�+u:J��])ޕRS��E�]]�]]��7U|SeGEGeGEGeGEGώ=sz��3�GNϜ9=sz��3�G��.�s�b+��3_s��bL#��2��~_�;��I��

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