fuel sender

Thanks for the info, i will have to have a look to see whats up with mine.

I wrote this the other night as I am getting bored of repeating myself on the phone... http://www.daihatsuhijet.co.uk/fuel-gauge-and-light-sender-wiring-daiahtsu-hijet-paiggio-porter/

Next pages on the list are LSPV, and testing sensors.

Nice write up mate, gives me a better idea of what to look for  

Smurf failed MOT on the brake pipes that go over the tank. As guage doesn't go below half I asked them to remove the sender so I could repair/replace it. When they showed it to me it was obvious the cap has fallen off the end so they're going to fish it out and solder-melt it back. Thanks for all comments, especially HJ's write up. Couldn't find Logi's pics on the subject though - a link to this thread might be useful?

Top man, Logi. Garage 'soldered' bottom of sender back, refitted tank and gauge didn't work at all! They took it off again and I've got the sender now - connected it sender to a multimeter and tipping it up showed a change in resistance on black/white cable to earth tag. However, on lowering it into a bucket of water it registers going in, but no change coming out until I knock it against side of bucket. Anyone know if they're ueuslly slow to respond or maybe mine is sticking?

Did they put the float in the right way?! Hmmm

I don't think the float ever came out - but would that make a difference? I can float upside down!

Well you took it to a garage, these professionals did the hard, labour intensive bit of taking the fuel tank out, so I am sure they must be capable of solving this small simple issue. I guess they will have noticed the floats contact teeth sit different if you put it in one way or the other. And I am sure they will have googled "fuel sender hijet" and read a few pages that would have given them some tips of the issue.

I never noticed a "right way up" on mine? Either I'm lucky or it don't matter?
What i reckon is the centre bits a wee bit bent, just enough to catch. When the bottom bit falls off it allows the centre bit to move causing the float to stick, if the central part isn't properly in the slot in the bottom bit it sticks, and its not much between stick & move.

If you don't stick the pcb in that slot in the cap then the board will sit funny.

The contacts on the float sit in the pcb contacts differently depending on the 4 possible ways the float can go on.

My fuel gauge comes up and get stuck on 10%. Switching of the engine the needle goes down as it should. The low fuel light does it's job.

a. Should, can I repair it or should it be replaced?
b. Is it possible to get the fuel sender out without completely to remove the tank?