hi folks, am embarrassed to ask this but here goes.. i removed the 2 access plates in the rear seat box and accessed the fuel tank this way have replaced the fuel filler neck as the last owner had done a right bodge job on it and thats all sealed and looking good. so i have taken off the old fuel sender unit for my late bay double cab and have tried to fit the new one back and for the life of me cant get it to fit.. I have a new rubber seal and have tried pushing down and turning it to refit it but cant get it sorted. anyone got any tips or a diagram to help me see what i am doing wrong? is there a knack to this that i am missing? sounds easy enough but its not easy fitting into the rear seat compartment as I am not a small bloke.. so any tips are appreciated!! thanks!
IIRC There’s one tab on the sender and corresponding slot on the tank which is marginally wider than the others meaning it only goes in, in one orientation. It’s just like a cassette on a bike if you’ve ever done that. If you are forcing it that much, it’s probably not right
The seal has to be tight, you might have to knock the sender round with a blunt screwdriver/hammer. Easier when you're tackling it from above.
If the old one was not leaking and still provided a fuel reading, you might want to put it back after trying the new one with its "different" interpretation of the level of fuel ... despite what it looks like. But if the old one was original VW and the resistance wire has worn out , keep it - as there are people experimenting with re-winding them with the correct resistance wire and restoring them to working condition and reading sensible fuel tank levels.
