Vauxhall cavalier gsi petrol gauge

[bigsilver]

My petrol gauge on my gsi has stopped working what's the first things to check any help appreciated

[iangsi]

Has it stopped completely ? as the one in my GSI would not read above half a tank I changed the sender unit in the tank & that sorted it out. You could unplug the connector at the sender unit & short it out with a piece of wire & turn the ignition on to see if the gauge reads

[Robsey]

It is better to try a 120 ohm resistor across the tank connector.

A direct short may kill the gauge as it would cause an instaneous full deflection of the fuel gauge.

A 5 watt resistor at 120 ohms should give a reading just above 1/4 tank.

A total loss of fuel gauge suggests a broken wire or corroded connector pin in the sender plug.
The plug is in the gap between the tank and the rear footwell.
A nice place for mousture and muck to collect.

If the connector and wires seem okay, it is likely that you have a dead gauge.

[bigsilver]

Cheers robsey n Ian the thing iz working again ,

[Robsey]

What was the cause of the gauge fault?

[bigsilver]

Hi robsey not looked at it as yet but is working the now , robsey can't seem to source part to fit my clutch looking for the 3 small clamps to keep pressure plate clamped tool number KM526A , tried vauxhall but they don't stock any more any ideas where to get them . want to do clutch at weekend .cheers robsey

[Robsey]

Try your local motor factors... all three factors near me had them hung up, the last time I popped in to see them.

[bigsilver]

Hello robsey, been a while ,I dropped the tank and the plastic plug has snapped of the sender unit ,I take it its definitely a sender unit I need now ,where can I get one from ,cheers

[Robsey]

You could try asking your local auto factors.

"Back in the day", they used to carry a few generic sender units that would work on various models, including the Cavalier mk3.

Ah - see you have a4x4 turbo with IRS.

Only on part number comes up on EPC.
90228564, which was replaced by 90510445....
Time to go hunting.

[Robsey]

I have seen two hits for the later part number.
(None currently on ebay)

Genuine Parts search are quoting £155

Another online supplier is quoting £206.

Youch - both are very expensive.
I would have a good look round, for a better deal, or a used part.

[Robsey]

According to the listing, the part is used on -
Calibra - 1989 to 1997
All models.
Upto chassis number -S9000454.

Cavalier - 1989 to 1995
20NE, C20NE, 20SEH, 20XE, C20XE and C20LET.
For "2000", GSI, TURBO and 4WD
Upto chassis number -S1008892

So if you can find one in a scrap yard...

Looking at the image, it is a unique design mounted on the top face of the tank, with a twist / screw on securing ring.

All standard Cavaliers have a completely different horizontally mounted sender.

[bigsilver]

Waiting kn a guy getting bk to me with a price, worst scenario could I get away with drilling a small hole on cap and soldering wires on the wires in the sender stalk ,

[Robsey]

Only one way to find out.

Solder on the wires, and seal with epoxy-resin or something to create a good seal.

The sender is potentially broke anyway, so you have nothing to lose.

[bigsilver]

Hi robsey I've desoldered the wires from the plug inside the cap and ran 2 wires onto the them and pushed them into the connector and its working fine ,what should a buy to seal hole once I drill ,or what exactly am I asking for and where could I get it ,cheers tam

[bigsilver]

Would silicon do the job robsey

[Robsey]

As said, I would use 2 part epoxy resin.
You can even get it from some of the pound shops.

It is more durable than silicon.
Besides, I am not sure if petrol would soften or dissolve silicon.

[bigsilver]

Ok mate