Operating instructions
CAUTION: Before drilling any holes into the tank, place the
sender assembly on top of the tank to judge the proper hole
placementone that will allow the float arm clearance inside
the tank.
SAFETY PRECAUTION: When making modifications to
fuel tanks, it is essential that the tank be removed from the
vehicle, and that it is empty, clean and dry. After drilling, make
sure all chips and other foreign matter have been removed from
the tank. Clean the tank thoroughly.
If no holes exist in the fuel tank (see CAUTION, above):
1. Carefully mark an area to be cut open so you can insert
the sender. The key to this step is to position the float
as close as possible to the center of the tank. This pro-
vides the most stable and accurate reading when the
fuel sloshes back and forth. Make sure you have al-
lowed enough clearance for the float arm before you cut
the hole. Remember, you only get one chance to do it
right!
2. Cut a 1.697" (43 mm) hole in the top of the tank.
3. With the gasket in place below the flange, carefully feed
the float arm and sender body into the 1.697" (43 mm)
hole in the tank. Make certain the float arm has free
motion within the tank. Using the sender flange as a
template, locate the positions of the five mounting holes.
Depending on the thickness of the tank, either self-tap-
ping screws or #8-32 machine screws may be used, drill-
ing and tapping accordingly. If threaded holes already
exist, check the thread size and use the appropriate hard-
ware.
4. Insert the fuel sender assembly into the tank and apply
gas-proof sealant. Align the holes and thread in the ½"
mounting screws through the holes in the sender flange
and tank. Check to make sure that all screws are se-
cure. AVOID OVERTIGHTENING! When you have
done this, the installation of the fuel level sender unit is
complete.
Temperature and Pressure Sender Installation:
Check the OEM engine manual for the correct location for these
senders. Temperature senders are most accurate when installed in
an aftermarket intake manifold. Installing the sender into the
cylinder head can cause high readings due to exhaust manifold heat.
NOTE: This kit contains a
3
/8 " 18 NPT temperature sender, and
a
3
/8 " 18 NPT to ½" 14 NPT adapter should you need it.
CAUTION: Do not use tee, angle or reducing adapters for
temperature senders, as the tip may not be immersed in the
water flow. Do not use teflon tape on sender threads. It will
interfere with the electrical ground. Senders have self-seal-
ing, tapered pipe threads.
Speed Sensor Installation:
The speed sender included for use with the programmable speed-
ometer in this VDO Instrument Kit is a standard, closed Hall-effect
sender. It is a closed sender with
7
/8" 18 NPT fittings for GM and
many other transmissions. It sends a 16 pulse-per-revolution signal
in a three-wire configuration.
(A standard, through Hall-effect sender for use with cruise control
is available from your VDO dealer (Part Number 340-012). Other
senders which can be used with the programmable sender include
Ford [through or closed] Hall-effect senders or almost any induc-
tive sender.)
1. If you are replacing an existing speedometer: Remove the cable
that went to the old speedometer.
2. Install the new sender in the place where the old cable was bolted
onto the transmission.
or, in a new installation:
1. Bolt the sender onto the transmission at the location specified by
the OEM for speedometer cable installation.
2. Run the eight foot length of wire to the new speedometer.
3. Cut it to length, and attach it to the new speedometer according
to the instructions in the separate, enclosed speedometer installa-
tion and operation instructions.
Diagram F
Standard, closed, 3-wire Hall-effect sender included in kit
Diagram E
Fuel Sender Assembly and Hole Pattern Dimensions