Fuel sender - pipe union?

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Peep110

Member
Posts
51
Location
Oxford
Just replacing my fuel sender on my 300TDI and the plastic pipe on the old one snapped as I tried to undo the fuel connection.

Looking at it away from the vehicle I don't see how it would have been possible to undo it without the pipe snapping, particularly as it took a fair bit of effort to undo the union anyway!

So now, the might seem a daft question, but the union had a small brass-like olive in it and of course the Britpart replacement kit didn't include a replacement, so is it ok to just cut the pipe and shove it onto the new sender with a pipe clip round it?

Also, and just in case anyone else is doing this (or thinking of doing it), beware of the baffle plate and the fuel return pipe(?) inside the tank which both do their very best to get in the way of the float and pick-up pipe as you struggle to get it in!! I found it best to take it back out and shine a torch into the tank so I could see where these obstacles were, and then try again with more success :)
 
A quick update, but first a disclaimer: I am merely describing my method of solving a problem. I do NOT claim it is an ideal solution, and I will NOT advise anyone that my method is better than the standard or accepted procedure(s), whatever they may be. If you choose to do as I have done, and it works for you too then that's great but I will NOT admit or accept liability for any problems or issues arising from anyone copying me.

Anyway, I did not cut the original pipe clamp off of the pipe in the end, I wasn't sure if the actual fuel pipe would fit or reach onto the plastic spout on the sender. Also, there was no way I could have got the crimp tool in there to do a squeeze-shut pipe clamp and it wasn't going to be too easy to get to a jubilee clip to do it up. So I eventually decided to re-use the original (cleaned up) clamp but with two small O rings instead of the "olive" style original seal. I put the first part of the two-part pipe clamp onto the spout, then carefully pushed in an appropriately sized O ring, then seated it by screwing the second part of the clamp in and then out again, and then pushed in a second ring. The combination seems to be working fine so I'm happy with that. You do seem to need two though, the clamp doesn't want to screw shut sufficiently to squash a single ring onto the spout but with two in there it does.

I do appreciate that the purists out there reading this might be gasping in horror at my tale, and no doubt some may be inclined to tell me the errors in my ways, but there are no leaks so far (even with a full tank) and nor are there any air bubbles in the fuel reaching the engine, so I'm happy.
 
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