ISSPRO R89890 - Manual (Page 2)

Form IS122 (Rev. C 6/6/03) Page 2 of 2
Assembly Procedure
To install fuel level sender for fuel level gauge proceed as follows:
1.
Disconnect battery at ground terminal.
2.
Before fitting sender to tank, test the unit with jumper wires and multimeter. Be sure the ohm readings at empty,
half, and full corresponds with gauge.
3.
Remove old fuel level gauge and sender assembly. Some senders may require disassembly before removal (drain
tank and remove from vehicle if necessary).
4.
New sender must be adjusted to fit fuel tank. Adjust lengths “A” and “B” for sender by using the table provided
on the other side of this page. See illustration.
5.
Adjustment of length “A” is accomplished by bending the Arm end 90
° to dimension “A”, then cut off wire to
0.32” as shown.
6.
Adjustment of length “B” is accomplished by loosening set screws and adjusting bracket to specified length
before tightening. (If existing tank gasket is used between tank and unit, add the thickness of the gasket to
dimension “B”. See table on front page.)
7.
Cut off bracket so that the distance between the housing and the end of the bracket does not exceed the length of
the bracket. (Limited to length of wire supplied, excess wire should be coiled around bracket.)
8.
Install gasket onto bracket and determine arm movement position (see index table below) for tank application. It
may be necessary to remove hardware bracket to flange in order to re-position arm. Assemble hardware in the
same manner as it was removed.
9.
Attach float arm into hole in housing lever and crimp housing lever around rod tightly.
10.
After adjusting, install new sender in fuel tank. Tighten all fasteners and connect fuel sender to proper fuel gauge
terminal “S”, using appropriate ring terminals.
11.
If a separate ground wire is supplied or existing, use ring terminal and fasten down with nearest mounting screw
on flange.
12.
Ensure sensor arm movement does not come in contact with the inside of the tank.
13. Reconnect battery.
(RH) Pos 1 Pos 3 (LH)
Pos 2 Pos 4
Index Table