Fuel Sender no longer available! Help!

[ott11ma]

Hello all

my mk 2 petrol tank leaks from the top sender when the tank is filled up!

I have got a new rubber seal (from GSF) - looks like a basic O-Ring 58mm... but I cannot get hold of a new sender unit - I have tried VW Dealer, GSF, Euro car parts, VW Heritage (who checked with their german suppliers - no stock).

I am worried if I try to open/remove the current sender (to replace the seal) that the plastic might break (is that a common problem??), so I really want the comfort of a new sender sat next to me before I try this...

Does anyone have any suggestions where I can get hold of one? (its a 1.8 carburettor EX engine).

Thanks

Tim

[bengould]

Probably time to go scrap yard hunting. I do have a spare, but I have just broke the one in my car trying to remove it. lol.
You can get one from any 1.6 or 1.8 carbed car as long as the fuel tank is the same size as yours. You may even be able to use one from a different sized tank I am not 100% sure though.

Yes it is a problem that the plastic can crack when you take it off due to it being old and brittle. They do come out if your careful though.
My usual method is a 3/8 extension bar and a rubber mallet. Put the ratchet end of the bar on the sender and hit the socket end firmly but not too hard. With a bit of persistence and working your way round the 4 notches on the sender so not to put too much stress on each one, it will come out. It only needs to turn 1/8-1/4 of a turn.

You can also make a wooden tool to fit into 2 opposite notches.
Kind of like this....

And then just twist it by hand.

Or, Just don't fill it up.

Ben.

[ott11ma]

Thanks for the help - I managed to buy a second hand sender from someone breaking a later GT11 via ebay. And a brand new seal (looks like a basic O-ring to me, but GSF still managed to extract over a fiver from me for the privilege - the seal is still available from my local VW dealer for a similar price!.

All fitted and no longer leaking when tank is full...

[mr.brown]

For future reference any carbed mk1 Cabby from B reg onwards should have the same sender. Worst case - as the tank is identically shaped on carb and injection cars - you might be able to install the lift pump and just wire up the sender and block off the fuel pipes.