Rodeo fuel sender fault

Submitted: Monday, Dec 07, 2009 at 14:27

ThreadID: 74241 Views:15881 Replies:4 FollowUps:4

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Skellem

Hi, I am new to ExplorOz and would like some assistance with a problem I have with my fuel sender unit on a 2003 Holden Rodeo 3.0L Tdiesel RA 4x4.
It indicates 3/4 full when I fill up to the top at the servo, and the empty light comes on at around 35L of a 76L tank. I have been qouted ridiculous amounts of money to replace the unit and as an electrical techo I'm interested to know if the unit is sealed or can be repaired or replaced without replacing the pump (and without having to drop the tank and pull it out to find out the hard way). I have a copy of the workshop manual which isn't really helpfull with this problem.
I am taking my family around Oz for a year and would like to fix this before we leave in January.
Thanks

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Reply By: Rangiephil - Monday, Dec 07, 2009 at 16:27

Monday, Dec 07, 2009 at 16:27

To me it just sounds like the sender arm has been bent.

Even new cars usually have an arm attached to a float which has a contact that swings over a resistor.
Why not pull it out and have a look?
A quick bend of the arm downwards will let it indicate full and also change the red light setting.

Regards Philip A

AnswerID: 394081

Reply By: Skellem - Monday, Dec 07, 2009 at 19:13

Monday, Dec 07, 2009 at 19:13

Hi RangiePhil,
The cheapest price I was given for a replacement unit was $350 and over $550 from Holden.....so I'll definitely give it a go. Both where genuine DELPHI units, GMH are theives.
It's a real pain on a long trip not knowing exacly how much fuel you have. I'll drop the tank and pull it out when I have a spare moment. Not too many of those as Christmas approaches and our big trip is getting closer.
Thanks for the input and have a Happy Christmas.
Skellem

AnswerID: 394101

Reply By: Mogul - Monday, Dec 07, 2009 at 20:21

Monday, Dec 07, 2009 at 20:21

It's a design fault and Holden cannot fix it. My RA has had 6 yes 6 different fuel senders in it all with the same result, no difference. In the end I was told it was normal and now I just live with it.

AnswerID: 394109

Follow Up By: Rocko Wallaby - Monday, Dec 07, 2009 at 23:01

Monday, Dec 07, 2009 at 23:01

Have a Holden Frontera...same sender/fuel pump unit, I believe. Exactly the same problem. It's a damned nuisance, but that's life.
Tried taking the fuel tank and sender out...bent it a bit...played with it a bit...cleaned it out a bit....did nothing ;)
Least it hasn't gotten worse in 200,000km
Scotty

FollowupID: 662370

Reply By: D200Dug- Monday, Dec 07, 2009 at 21:30

Monday, Dec 07, 2009 at 21:30

I have a 2008 rodeo and the empty warning light comes on pretty early usually around 55 to 60 lt down on a 76 lt tank.

I am wondering if it would be better just to ditch the factory tank, I believe there is an after market 130 lt tank available.

AnswerID: 394123

Follow Up By: Member - Barnray (NSW) - Monday, Dec 07, 2009 at 21:39

Monday, Dec 07, 2009 at 21:39

Unfortunately they use your old tank unit. Barnray

FollowupID: 662349

Follow Up By: Member - Effie C (NT) - Monday, Dec 07, 2009 at 22:48

Monday, Dec 07, 2009 at 22:48

True longranger use the oringal sender but som how they get it to work with their tanks (129 Litre) only drama is that the gauge does not budge from full till you have used the additional fuel and get down to the 75 litre mark and then work as per normal. Ours went from as described above of the fuel light coming on at 35 litres still to go to a respectable 10 litres to go