[AndreJ]

Hi
I have a gen. 3 Pajero 3.5 , my fuel gauge is working when it wants to, sometimes even 10 minutes after I started driving it starts to come alive then goes right up to the full position en slowly settles to where it should be, do you guys think this problem is in the float or the fuel gauge or the pc board behind the dials
Any help will be appreciated

[AndreJ]

Does anybody know how to get to the fuel sender unit, do I need to drop the fuel tank or can I get to it from the inside under the carpet like the early models and is the sender unit part of the fuel pump or separate, any info will help thank you

[AndreJ]

ok , so I figured it out on my own, and this is what I did.
First remove the middle seats

Then remove the A/C vents from the carpet and the top cover plate for the fuel pump that sits under the seats.
Then rol up the carpet and you will find the cover for the fuel sending unit
about in the middle where your feet goes when you sit on the seats
Unscrew the cover and unscrew the sender unit , unplug and slowly pull it out.
you need to take off the metal plate to get to the thingy that goes up and down , I just cleaned it and sprayed some electro clean on the parts and then tested it to see if it works.
while testing move the flout up and down too see if you get different readings ( must be pluged in and car ignition on- not started)
you can then also test to see if your fuel light works

sorry the photos is from end to start

[Nick Gibson]

Hi Andre

Thanks for the good post, I did the clean this weekend and all is good with my gauge again! I did however find this box, see my other post) under the rear seat, do you recall seeing one in your pajero as well?

[Nick Gibson]

Sorted, see my other post. It was a tracking device.

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[MThompson]

Hi Andre

Thank you for the very helpfull post.

Do you think procedure will be the same for the diesel? I know the location for the gauge is the.same. Was there any seals you had to replace or something?

Any issues after you cleaned everything and reinstalled? My DiD's gauge is also acting up and want to get it sorted.

[RoelfleRoux]

Andre, great post - thank you

[Nick Gibson]

Hi guys, just to revive an old thread. I did the clean of the fuel gauge sensor in the tank, it works perfectly out of the tank, but not when it is inside. So I removed the plastic fuel tank cover, and found the dreaded dent right below the fuel sensor float...

Dent under plastic cover 1

Dent under plastic cover 2

I then removed the Seats and carpet and took out the fuel level sensor and fuel pump/filter assembly. I then drained the tank completely with the drain bolt and the last remnants with a home made catch bottle, two fuel hoses and rubber duck pump connected to the vacuum port.
I then mopped up the last drips of petrol and dirt with a rag in the tank to make sure it was as safe as possible to work in the tank. I then (with a fire extinguisher very close) took a thick wooden pole (pick handle) and a 4 pound hammer and proceeded to carefully tap the dent out through the fuel sensor hole. It moved out/down by approximately 40mm, and when I put the fuel sensor back in it worked through its full range as the yellow light came on immediately.

Dent pushed out 40mm

Please use this advice with extreme caution, petrol vapours are extremely flammable!

I also gave my fuel filter a bit of a clean/flush while I was there, I rinsed it out in reverse with clean petrol - lots of rusty debris came out, will have to get a new on as soon as I can.

Fuel pump & filter assembly

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[Nick Gibson]

I thought should post my home made catch bottle, I used a rubber duck pontoon inflator pump to create suction to drain my fuel tank of the last 4 liters, worked quite well!

Catch bottle

I put one hose into the tank and connected the other to the pump suction, and as soon as the bottle was nearly full I emptied it out - very dirty petrol! Better than mouth-fulls of petrol trying to siphon