Running a wire through the car

^thats the one you want

Looks like I need a new tank

Can't seen to move it or even destroy it with such a tiny hole.

The boot is a different number but looks exactly the same, and the problem is more the plastic plug being too long because the actual unit sits fouah but my old one is slightly recessed so the plug will sit lower looks like I'll just have to trim the plug down 

does fuel still flow nicely out of the outlet on the bottom of the tank? if so you could use a facet pump or whatever on that outlet to fill the swirl pot. just a case of is there room underneath…

mazza whats the part number? dunoo if its just the angle of the pic but it does look a bit taller than the one in rich's pic

rubjonny said

does fuel still flow nicely out of the outlet on the bottom of the tank? if so you could use a facet pump or whatever on that outlet to fill the swirl pot. just a case of is there room underneath…

Yesterday I heated up a blade and hot cut the sides of the swirl pot. 

I found my multitool was broken so couldn't use the flexi shaft and cutting disc.

Going to machinemart in a bit to get a drill flexi shaft which should do the trick.

To anyone else please don't use anything red hot in the fuel tank unless you know for certain it contains no fuel!!!

I was OK as this had been  restored by a company who cleaned the tank and lined it with an anti rusting compound. 

rubjonny said

mazza whats the part number? dunoo if its just the angle of the pic but it does look a bit taller than the one in rich's pic

John is right, mine is not as tall as your picture. I will get a better shot later

It is a different part number but I have chopped it up and bent the pins because it was miles too tall and it is now just squished down and it works fine, I know this because it fired up first time  

mazza411 said

It is a different part number but I have chopped it up and bent the pins because it was miles too tall and it is now just squished down and it works fine, I know this because it fired up first time  

Great news

I wish I was having more good news lol got to finish butchering the swirl pot to fit my lift pump!

Just brimmed the tank and noticed that it doesn't go all the day to the top of the fuel gauge  so either the sender is broken/wrong or it needs bending a bit to get the resistance right on it 

Nothing is ever straight forward is it!? 

I have the same problem as you with this. I fitted my carb fuel tank this morning and installed the sender. It will not go in the other direction as John suggested as the fuel sender ball hits the back of the tank plus the fuel lines have no where to go!

I do however have another sender which has the outlets pointing diagonally outwards towards the connector plug which is horizontal not vertical like the sender you have. I'm really confused about this as the original senders connector doesn't fit anymore.

I could use the other sender but that would be cheating :p

This is the one that doesn't allow the connector to fit correctly:

Polo sender?






This is the sender which seems to work OK as the putlets are pointing towards the engine and the connector is at the front giving you clearance.

Cabriolet sender?




 

Should have got a cabby one  might also solve the issue of my fuel gauge not working properly 

yeah the polo and cab are slightly different, for the level sender issue try tweaking the float arm a touch might have got bent at some point

With the polo sender if you do fit it the other way there is nowhere to feed the fuel lines over the top of the tank without bending the lines 180 degrees and going down the back of the tank.

I'm sure you could get the Polo sender right with some tweaking but as I have the cabriolet one it makes it easier.

I have just switched everything over to the cabriolet sender for simplicity.

the thing is, i compared the polo sender to my golf one and they seemed exactly the same as in theri depth when fully lowered so maybe at its highest point on the resistor thing it hits the top of the tank, i dont know

it seems to be very similar to my old one when its at 1/4 tank (roughly 150 miles)  so might just leave it for now   mayvbe get a cabby one and another connector in the future

John I connected up the fuel lines this evening on the sender but the W2 mikalor 12-22mm worm drive hose clips touch the sender and the inspection cap when closed. Will this cause any earthing issues?

What slim line clips can I use instead?

it wont cause any earthing issues, the mk2 level sender clips are much thinner but are a bit of a git to work with. they are like a hook and clip style arrangement, you need side cutters or nips to get them to clip together.

pretty sure thats what would have been used originally on the cabrio senders too

Cheers John, won an auction last last night for 111 spring band mikalor clips so will swap it over when they arrive

I've just noticed that the gti fuel tank cover plate actually has a rounded top which looks like it would solve the issue of the plug interfering with the flat cover plate found on my car. Too late for me now but if anyone else has this problem then I think swapping the plate would be a solution