Diagram D Parts of the Fuel Level Sender Unit to be Adjusted

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Leslie Crawford
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2 Fuel Level Sender Installation: The fuel sender in this kit has a resistance rating of 10 ohms when the tank is empty and 180 ohms when full. The unit can be adjusted to reqd accurately in tanks from 6-23" in tank depth. For sender adjustment refer to Table 1 and Diagram C. I. This fuel sender is designed to mount on all fuel tanks with a standard SAE five-hole flange configuration. If you tank does not have this configuration it may be necessary to purchase our optional flange kits refereed to on the front page of these instructions. II. Measure the tank depth of your fuel tank. Locate this demension in Column A of Table 1.. Reading across to Column B you will find the dimension from the mounting flange to the float pivot you will need to adjust the fuel sender to. If this dimension is 15-1/2" or greater proceed to Section A for adjustment details. If less than 15-1/2" proceed to Section B for adjustment details. Section A: (Tank depths less than 15-1/4") 1. Loosen the two screws marked 'd' in Diagram D. Adjust the plastic housing up or down until the proper dimension from Table 1 is obtained. Re-tighten screws until secure. Section B: (Tank depths less than 15-1/4") 1. Remove nut 'a' and washer 'b' to wire lead. 2. Remove two screws marked 'd' and discard. 3. On reverse side of sender locate two screws in plastic housing marked 'e'. 4. Slide plastic housig off of bracket 'f' and discard. 5. Install plastic housing by sliding on to bracket 'g' and reinstalling screws loosely. 6. Slide housing up or down until proper dimension from Table 1 is reached, then tighten screws. 7. Rap excessive lead wire around bracket 'g' and re-install with nut and washer. Float Installation: 1. Loosen pivot screw 'h' removing shot metal rod show in Diagram D. 2. Install float rod to proper dimension found in Table 1, Column C and tighten pivot screw. Note: You must install so float ball is positioned to the sender body, when the float pivot is facing you. If you have found that your gauges reads backward after installation you have installed the float in backwards. To correct this you must disassemble and reposition the float. 3. Leaving 1" of float rod exposed on left of float pivot cut off excess float rod. As received, the unit will have a short lever arm installed. Loosen the screw and remove the short lever arm, and replace it with the long float arm and plastic float ball assembly. When the installation is finished, the arm length to the left (short side) of the screw must be 1".!! IMPORTANT!! CAUTION: When attaching the float arm to the sender body, make sure the float ball is to the right side as you face the unit, as shown in Diagram D. If you attach the float arm to the left of the sender body, or backwards, the fuel gauge will read FULL when the tank is actually empty! Diagram D Parts of the Fuel Level Sender Unit to be Adjusted Note: In some installations if it is necessary to have the float pointed in the opposite direction. to accomplish this do not reposition the float. You must remove the two screws marked 'd'. Slide plastic housing off of bracket, rotate and reinstall to the proper dimension. CAUTION: Do not overtighten hardware, to avoid damage to the threads! WDQN &µ IXHO OHYHO VHQGHU %µ IORDW $µ Diagram C Measurements Needed To Make Proper Adjustments Page 2 TABLE 1 (dimensions in inches) A B C A B C A B C

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4 VOLTAGE WIRING OF POWER AND GROUND TO EACH GAUGE LEGEND Sender Wire: S or G Wire: or 12Volt Wire: () Diagram G Wiring Diagram ILLUMINATION WIRING AND WIRING OF SENDERS TO EACH GAUGE fuse dashlight switch pressure sender temperature sender fuel sender Electrical Wiring: Refer to the wiring diagram, Diagram G. Wire gauges in series from a positive () accessory to a source which is not already overloaded with fans, air conditioning, and such. The ground ( ) wire is also run in series, including the light socket ground. The final ground run, using 14-gauge wire, should be connected to a good ground such as the engine block ground strap or directly to the negative battery post. NOTE: See the separate Speedometer Installation and Operation Instructions for information on wiring the speedometer. System Testing: When installation and wiring has been completed, the following tests should be performed to ensure that all systems are functioning properly. I. Turn on the dash light switch to see if all gauges light up. If not, check your wiring, the ground, and all bulbs. Reconnect or replace as necessary. II. Turn on the ignition key. Gauges should read: Pressure: Needle to 0 Fuel: Needle to amount of fuel in the tank Temperature: Needle to the temperature of the engine water a) With the key on, pull the sender wire off of the sender: Fuel and pressure gauges: needle to the right-hand position Temperature gauge: needle to the left-hand position b) With the key on, ground the sender wire to the engine block: Fuel and Pressure Gauges: needle to the left-hand position Temperature Gauge: needle to the right-hand position NOTE: All VDO electrical gauge pointers will peg full lefthand position when the key is off. III. Senders can be tested with an ohmmeter that measures from 10Ω to 2000Ω. Connect the positive () lead from the tester to the sender terminal, and the negative ( ) lead to a good ground. The following readings should occur if the sender is operating properly: Temperature sender engine cold: 700Ω engine approximately 180 : 68Ω Pressure sender engine off: 10 Ω engine running 40 psi: 105 Ω engine running 60 psi: 152 Ω IV. Voltmeter: Volts: Key on, engine off: 12 Engine running, no accessories or lights: Engine running with accessories, lights: NOTE: These readings are approximate, depending on the regulator system and engine speed. Lower readings indicate a bad battery, regulator, or alternator; or incorrect wiring. V. With VDO fuel tank senders (Part # ), an empty tank will read 10Ω. As fuel is added, the resistance reading will rise until the tank is full, when it will read 180Ω. NOTE: If you already have a fuel level sender in your tank, check the resistance readings. If they do not match the readings above, VDO manufactures a number of fuel gauges which should match your sender. REMEMBER: The ohm range of the sender and the gauge MUST MATCH! VDO North America warrants all merchandise against defects in factory workmanship and materials for a period of 24 months after purchase. This warranty applies to the first retail purchaser and covers only those products exposed to normal use or service. Provisions of this warranty shall not apply to a VDO product used for a purpose for which it is not designed, or which has been altered in any way that would be detrimental to the performance or life of the product, or misapplication, misuse, negligence or accident. On any part or product found to be defective after examination by VDO North America, VDO North America will only repair or replace Siemens VDO Limited Warranty Page 4 the merchandise through the original selling dealer or on a direct basis. VDO North America assumes no responsibility for diagnosis, removal and/or installation labor, loss of vehicle use, loss of time, inconvenience or any other consequential expenses. The warranties herin are in lieu of any other expressed or implied warranties, including any implied warranty of merchantability or fitness, and any other obligation on the part of VDO North America, or selling dealer. (NOTE: This is a Limited Warranty as defined by the Magnuson- Moss Warranty Act of 1975.) Siemens VDO. Phone:

5 Hour Meter Terminal Hour Meter Terminals ( ) Clock Terminals ( ) Diagram B Clock Wiring Diagram Constant 12v ( ) ( Pressure ) Option 1 - Diagram C Engine Hourmeter Wiring Diagram Option 2 - Diagram C Engine Hourmeter Wiring Diagram DO NOT OVERTIGHTEN! SiemensVDO Limited Warranty Siemens VDO warrants all merchandise against defects in factory workmanship and materials for a period of 24 months after purchase. This warranty applies to the first retail purchaser and covers only those products exposed to normal use or service. Provisions of this warranty shall not apply to a Siemens VDO product used for a purpose for which it is not designed, or which has been altered in any way that would be detrimental to the performance or life of the product, or misapplication, misuse, negligence or accident. On any part or product found to be defective after examination by SiemensVDO, Siemens VDO will only repair or replace the merchandise through the original selling dealer or on a direct basis. Siemens VDO assumes no responsibility for diagnosis, removal and/or installation labor, loss of vehicle use, loss of time, inconvenience or any other consequential expenses. The warranties herin are in lieu of any other expressed or implied warranties, including any implied warranty of merchantability or fitness, and any other obligation on the part of Siemens VDO, or selling dealer. Siemens VDO. Phone: Siemens VDO Clock/Engine Hourmeter Installation Instructions Instruction Sheet # Rev. 10/03 -!"f C A UT ION: R ea d these ins tructions thoroughly before making installation. Do not deviate from assembly or wiring instructions. Mounting Nut direction depends on panel w idt h A: 0.4" (0 10 mm) CAUTION: B: Read.4".8 " (10 these 20 mm) instructions t ç TOP: VDO s Spin-Lok ä Mounting Clamp LEFT: VDO Mounting Bracket Diagram A - Mounting using optional VDO Mounting Bracket or VDO Spin-Lok Clamp é Instrument Mounting Diagram A: 1. Prior to any work on vehicle's wiring system, removing the (-) negative battery cable from the battery to disable battery power. 2. Find a suitable location to mount the instrument where there is ample depth to secure and wire instrument. 3. Cut a 2 1/16" (52 mm) diameter hole in the location selected. Instrument should fit into hole easily without forcing. Forcing it may cause damage to housing of instrument. 4. Secure 'Spin Lok' clamp (Diagram A) on to instrument. (Note) the 'Spin Lok' clamp is designed to work in thin panels as well as panels up to.8" (20 mm) in thickness. Consequently, if 'Spin Lok' clamp is installed and will not securely fasten instrument, remove, reverse and re-install. 5. If you are using optional metal mounting bracket, install with mounting nuts, For thicker panels it may be necessary to trim legs accordingly. Clock Wiring Digram C: 1. Wire terminal to a fused 12 v battery source that is not switched off when vehicle ignition is off. 2. Wire - terminal to a good ground location. 3. If the instrument you have purcased test for operation. CAUTION!!! Secured with Spin- Lok or metal braket tight enough to prevent rotation of instrument. DO NOT OVER TIGHTEN INSTRUMENT OR DAMAGE WILL OCCURE TO HOUSING AND BEZEL. Hour Meter Wiring Option 1- Digram C: 1. Wire terminal to a fused 12/24v battery source that is switched off when vehicle is not in operation. 2. Wire - terminal to a good ground location. 3. If the instrument you have purcased test for operation. (Note) Since the hourmeter registers in 10 th of hours, it will take 6 minutes before hourmeter will show movement. Hour Meter Wiring Option 2 - Digram C: 1. Wire terminal to a fused 12/24v battery source that remains on even vehicle igniton is off. 2. Wire - terminal directly to a normally open engine oil pressure switch. When engine is started and oil pressure CAUTIO rises the pressue switch will close and CAUTION the hour meter will begin to operate. 3. If the instrument you have purchased start vehicle. When oil pressure present observe operation of instrument. (Note) Since the hourmeter registers in 10 th of hours, it will take 6 minutes before hourmeter will show movement. Clock Setting 1. Button on bottom left of clock face will set counter clock wise 2. Button on bottom right of clock face will set clock wise 3. By hold left or right button down will make the clock set faster