1992 mk3 Golf Gti 8v engine into my mk2 caddy van

Hi there. sorry to bother you again Just a bit stumped with my fuel gauge not registering correctly. It only shows slightly into the red even though the tank is over half full?

These are the things I have tried.
Moved the pump around to various positions as I thought the float arm was trapped, no joy..
I then earthed the turquoise and black wire and the gauge went to full..
I added an extra earth to the pump plug..no joy
I refitted the original diesel sender unit and the gauge worked perfectly . which proves the gauge and wiring is all ok ..
I also change the arm/float off the diesel sender onto the new pump(as it is longer) to see if that made a difference..no joy..
The pump I have fitted is a brand new mk4 golf pump which is the prefered choice when fitting a golf mk3 8v petrol engine into a caddy mk2 van.. It works perfectly regarding pumping fuel and have been on quite a few long trips with no problems apart from no fuel gauge reading.

If you can think of anything I have missed/can do It would be appreciated as I am totally stumped Thanks H

 

Ah forgot to mention, I have tested the pump with multimeter set to 200 ohms , and lifting and lowering the arm its registering ..

 

What is the resistance on empty half and full between the 2?

 

Hi the Empty reading is 56.3... half 145.1 .. full 197.1

Thanks H

 

.. That is on the new pump. will nip to the garage and test the original sender now .

 

Right so new golf mk4 pump reading .. Empty 56.3 Half 145.1 Full 197.1 (shows no reading on the gauge)

Original sender readings .. Empty 18.94 Half 88.18 Full 36.5 ( this does register the fuel correctly on the gauge)

Many Thanks H

 

thanks for your reply i think i will replace the original sender unit that will sort the fuel.gauge out and fit a inline fuel pump at side of tank could you recomend a suitable inline pump that will run my 8v petrol golf engine.

 

Ah thanks for that... On it

 

Right then .. cut the blue wire at the left and it re-soldered to the right as per your pic. Needle now does move from red which it didn't before, yeay ...... But needle seems to stick at just over 1/4 full mark and I definitely have more fuel than that in, probably 3/4 of a tank full of petrol?
Thanks again H

 

Yes hallelujah! been messing with this a week now. I have just tried moving the pump/float around and still seems to stay at 1/4 mark. Only thing I have noticed is the arm on the original caddy sender is quite a bit longer than the one on the new mk4 pump and the float points in the opposite direction. I am toying with the idea of swapping the arms over to see if that does the trick.. although I am sick to death of pulling that pump in and out lol

 

This is what is causing me all this trouble

 

Hi there just a quick one i've managed to get some g60 brake carriers and some drilled and grooved 280mm discs. Could I use my existing callipers as they were newly fitted or do i need g60 callipers to match the new carriers .. my previous set up was 256mm . Many thanks again H

 

Ok. Thanks very much for that. So do I remove the pin from the carrier and grind of a couple of ml off the length of the pin or the head of the pin?.. Thanks H

 

Ah ok right, thank you. Been barred from touching the van till after Christmas now, so will do that on the 26th
Thanks again and have a great Christmas . H