For Lever Arm Fuel Level Sender Siemens VDO Instruments

1 fuel Level Sender installation InstructionsFor Lever Arm fuel Level SenderPart #0 515 010 169 Rev. 7/03 Allentown, Pennsylvania USATHE instructions FOR installation OF Lever ARM fuel Level Sender FOLLOW. USE IS RESTRICTED TO 12 VOLT NEGATIVE GROUND ELECTRICAL WIRING instructions , REFER TO THE instructions THAT CAME WITH YOUR fuel Level and Hardware Kit1 Tools and Materials Needed For installation :2 1 16" hole sawDrill and drill bit setBolt cutter or similar toolHalf-round fileTape measure or rulerWrench or nut driver setPhillips screw driverUtility knifeGas-proof gasket sealantWeld-on installation Kit (optional) P/N 226 901 Bolt-on installation Kit (optional) P/N 226 451 CAUTION: Read these instructions thoroughly before mak-ing installation . Do not deviate from assembly or wiring in-structions. Always disconnect battery ground before makingany electrical connections. If in doubt, please contact yourdealer or VDO Instruments at (540) Level Sender InstallationThe fuel Level Sender has a resistance rating of 10 when thetank is empty and 180 when full.

2 Refer to the VDO Instru-ments Catalog for matching fuel gauges. The unit can be adjustedto read accurately in tanks from 6" to 23" deep. For Sender adjust-ment, refer to Table 1 and Diagram Measure the depth of your fuel tank. Locate this dimension inColumn A of Table 1. Column B then shows the length fromthe underside of the Sender flange to the center of the float C shows the distance from the center of the float pivotto the center of the float ball. For example, a tank 12" deep wouldneed a measurement of 6" from the flange to the pivot, and "from the pivot to the For tank depths less than 15 " it will be necessary to eliminatea part of the assembly. Otherwise, proceed to Section III. Refer toDiagram B and proceed as follows:1. Remove nut a, washer b, and ring terminal c from the underside of the mounting Remove the two screws marked d and Remove the two screws marked e from the plas-tic housing and save for later Carefully remove bracket f from the plastichousing and discard.

3 Replace it with bracket g in the housing and loosely re-install the two screwsmarked e into the Slide the housing up or down until the properdimension from Table 1 is reached, then tightenthe screws e Replace the ring terminal and its : Do not overtighten hardware, to avoiddamage to the threads!WDQN & % $ IOR DWIXHOOH YH OVH QG HUDiagram AMeasurements Needed To Make Proper AdjustmentsTABLE 1 (dimensions in inches) A B C A B C A B C !! IMPORTANT !!As received, the unit willhave a short Lever arminstalled. Loosen the screwand remove the short leverarm, and replace it withthe long float arm andplastic float ball the installation isfinished, the arm lengthto the left (short side) ofthe screw must be 1". Siemens VDO InstrumentsSiemens VDO Instruments Phone: 1-800-265-1818 Siemens VDO Limited WarrantyVDO Instruments warrants all merchandise against defects in factory workman-ship and materials for a period of 24 months after purchase.

4 This warranty ap-plies to the first retail purchaser and covers only those products exposed to nor-mal use or service. Provisions of this warranty shall not apply to a VDO productused for a purpose for which it is not designed, or which has been altered in anyway that would be detrimental to the performance or life of the product, or misap-plication, misuse, negligence or accident. On any part or product found to bedefective after examination by VDO, VDO will only repair or replace the merchan-dise through the original selling dealer or on a direct basis. VDO assumes noresponsibility for diagnosis, removal and/or installation labor, loss of vehicle use,loss of time, inconvenience or any other consequential expenses. The warrantiesherin are in lieu of any other expressed or implied warranties, including any im-plied warranty of merchantability or fitness, and any other obligation on the part ofVDO Instruments , or selling dealer. (NOTE: This is a Limited Warranty asdefined by the Magnuson-Moss Warranty Act of 1975.)

5 If no holes exist in the fuel tank (see CAUTION, above):1. Carefully mark an area to be cut open so you can insertthe Sender . The key to this step is to position the floatas close as possible to the center of the tank. This pro-vides the most stable and accurate reading when thefuel sloshes back and forth. Make sure you have al-lowed enough clearance for the float arm before youcut the hole. Remember, you only get one chance todo it right!2. Cut a " (43 mm) hole in the top of the With the gasket in place below the flange, carefullyfeed the float arm and Sender body into the " (43mm) hole in the tank. Make certain the float arm hasfree motion within the tank. Using the Sender flangeas a template, locate the positions of the five mountingholes. Depending on the thickness of the tank, eitherself-tapping screws or #8-32 machine screws may beused, drilling and tapping accordingly. If threaded holesalready exist, check the thread size and use the appro-priate Insert the fuel Sender assembly into the tank.

6 Alignthe holes and thread in the " mounting screws throughthe holes in the Sender flange and tank. Check to makesure that all screws are secure. AVOID OVERTIGHT-ENING! When you have done this, the installation ofthe fuel Level Sender unit is : Before drilling any holes into the tank, place thesender assembly on top of the tank to judge the proper holeplacement one that will allow the float arm clearance insidethe PRECAUTION: When making modifications tofuel tanks, it is essential that the tank be removed from thevehicle, and that it is empty, clean and dry. After drilling, makesure all chips and other foreign matter have been removed fromthe tank. Clean the tank Refer to Diagram C for installation of the fuel Sender assemblyinto the tank. The Sender flange is designed to fit a standard SAEhole : Make sure the float is installed as shown in DiagramB. Remember, if it is installed backwards, the fuel gaugewill indicate FULL when the tank is actually empty, andvice-versa.

7 Be sure to leave 1" on the short side of the To install the float assembly, loosen the screw marked h, remove the short piece of rod, and discard it. Insert the float roduntil the proper length the C length from Table 1 is met, thentighten screw h securely. Carefully cut off any excess rod with abolt cutter or similar tool, taking care not to damage the Loosen the two screws marked d. Adjust theplastic housing up or down until the proper di-mension from Table 1 is obtained, then retightenthe screws securely. DO NOT overtighten Re-install the ring terminal and its , tighten the hardware securely, but DONOT BParts of the fuel Level Sender Unit to be AdjustedIII. For tank depths of 16" to 23", no disassembly of the senderbracket is Remove the ring terminal as instructed inSection II, : 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 B. If you attach the float arm to the left ofthe Sender body, or backwards, the fuel gauge will read FULL when the tank is actually empty!

8 Diagram CFuel Sender Assembly and Hole Pattern Dimensions