Technical Aftermarket fuel sender plug doesn't fit

[lycopersicum]

Hello! The screw top that retains the fuel sender assembly onto the fuel tank broke some months ago and I've been struggling to find a replacement.

As far as I can tell it's this part which is common to many different cars: https://eper.fiatforum.com/Part/SearchPartByPartNumber?Language=en&PartNumber=46523405

However I've ordered two of these from various 3rd party brands and both turned out slightly too small, the inner diameter being about 3mm less than the original part. I just could not screw them on, I've had to cut the threaded ring open, fit it on the tank and clamp it in place with zip ties, which is obviously not ideal.

Any idea what might be going on here?

 

[ltz]

hey did you solve this one? I have a 2017 Ducato with same issue. The screw "nut" fitting for the pump unit is not fitting. Ordered several different ones from autodoc.

 

[lycopersicum]

Not made any progress on this and the zip ties are holding up fine so far. I might try to get an OEM part or 3D print one.

 

[ltz]

I'm, guessing that hinders you to fill the tank full? otherwise it will leak ?

 

[lycopersicum]

With the original part that was broken yes it was leaking when full. But not with the current repair, I've relocated the rubber seal to sit between the fuel sender and the tank, that way it makes a good seal even though the retaining ring is split.

 

[ltz]

oh nice! so how did you manage to get something to pull to from the tank? a long zip-tie around the tank fitting and then ties in to that?

 

[lycopersicum]

No basically what I've done is make a cut in the ring nut. That way it can be forced open a bit bigger and it will fit on the threads. Then I've put a zip tie around it (two actually, one was too short) to clamp it closed again. To stop the zip tie slipping upwards over time I've made notches in the plastic ribs.

 

[ltz]

smart! so you used the smaller new ringnut that was available for purchase and cut it in two. Ill try it!

 

[cid]

Hi, sounds like a very practical work around. I won't say bodge as that would be insulting. Do I understand that zip ties are the same as cable ties. If so, would a Jubilee Clip not be a more secure fix. It would have to be opened up to get over the fuel pipes and then closed again but you could tighten it more than zip ties and it wouldn't break. All the Best, Ian.

 

[lycopersicum]

Cable ties, yes. I considered a Jubilee clip but the issue was that the greater width of the band precluded locking it in place with notches in the ribs. Also the location is hard to reach through the access hatch and it wouldn't be easy to operate the tightening screw once in place.

I'm mostly concerned whether it will pass the (French) MOT.

I'm still confused why the aftermarket part doesn't fit. Fiat specifies a special spline tool for installing/removing this part so maybe it is meant to be very tight, but it can't possibly be *that* tight...

 

[ltz]

Will French MOT look at the top of the fuel tank?! Impressive Ill take some photos once I have copied this - also emailed Fiat to see if they have other products to provide.

 

[lycopersicum]

I'll try to post photos of my bodge too.. One word of advice, don't do this on a full fuel tank, the sender unit floats and pushes up quite hard which makes an already cramped job even more annoying.