xrs135
07-15-2019, 03:55 PM
After countless hours of scouring TVT, and reading up on every topic possible related to the fuel system, I've finally started my project of overhauling the fuel system. Our van is a 1988 Cargo 4x4 5SPD. I'm not necessarily doing a "complete" overhaul, but the plan is to replace the fuel filter, fuel pump, fuel strainer, try to get my fuel sender to work, and completely clean and reseal the inside of the fuel tank.
So far, I've thrown on the new fuel filter, dropped the tank, removed the fuel sender and fuel pump assembly, and have began the process of cleaning out the tank. I'm going to use the Lye method I read about here to clean the tank really well, and then seal it with POR-15 fuel tank sealer once it's all cleaned out. I'm also considering coating the exterior of the tank with original POR-15.
Problems/questions thus far:
1.) I bought an $80 set of flare wrenches for the removal of the main fuel line (where it changes from soft tubing to the metal fuel line. Even with the good flare wrench set, I ended up rounding out the smaller tube nut. Thankfully, I was able to get it all the way off with a set of vice grips... but needless to say the tube nut is toast. Does anybody happen to know what size and thread size of tube nut I should order for when I reconnect/re-flare the fuel line? I just want to make sure I order the correct one on Amazon.
2.) My gas gauge has been unreliable since day one of owning the van. With a full tank of gas, it shows between empty and 1/4 of a tank. Since I have the tank out, I wanted to investigate further. What I found when I pulled out the sender was a very clean looking "SEACHOICE PRODUCTS" fuel sender. Definitely not stock. I'm guessing this might be the source of my problem. I know that OEM fuel senders are no longer available, but are there any other *working* options out there that I should look into before I put all this back together again?
Thanks ahead of time for any input!!
**Photos show the presumably aftermarket fuel sender, and also the flare tube nut that I messed up and need to find a replacement for (I already cut off the old flare)
So far, I've thrown on the new fuel filter, dropped the tank, removed the fuel sender and fuel pump assembly, and have began the process of cleaning out the tank. I'm going to use the Lye method I read about here to clean the tank really well, and then seal it with POR-15 fuel tank sealer once it's all cleaned out. I'm also considering coating the exterior of the tank with original POR-15.
Problems/questions thus far:
1.) I bought an $80 set of flare wrenches for the removal of the main fuel line (where it changes from soft tubing to the metal fuel line. Even with the good flare wrench set, I ended up rounding out the smaller tube nut. Thankfully, I was able to get it all the way off with a set of vice grips... but needless to say the tube nut is toast. Does anybody happen to know what size and thread size of tube nut I should order for when I reconnect/re-flare the fuel line? I just want to make sure I order the correct one on Amazon.
2.) My gas gauge has been unreliable since day one of owning the van. With a full tank of gas, it shows between empty and 1/4 of a tank. Since I have the tank out, I wanted to investigate further. What I found when I pulled out the sender was a very clean looking "SEACHOICE PRODUCTS" fuel sender. Definitely not stock. I'm guessing this might be the source of my problem. I know that OEM fuel senders are no longer available, but are there any other *working* options out there that I should look into before I put all this back together again?
Thanks ahead of time for any input!!
**Photos show the presumably aftermarket fuel sender, and also the flare tube nut that I messed up and need to find a replacement for (I already cut off the old flare)