[C320-list] Fuel tank sender replacement for 2000 model

[Mark Cole]

Chip;

I replaced my fuel tank last spring with a new one from Ezell.  I called them (they are very helpful) to ask about removing and replacing the access plate and they told me not to put sealant on the gasket, but DO put some on the bolts.  They said they put a dab of Permatex #2 on each fastener since the tank is aluminum and the fasteners are stainless.  I found the Permatex at an auto supply store.  Like others have said, they warned against over tightening.  It should be the same for the fuel sender.

Mark
Fiddler’s Green #8

> On Aug 16, 2019, at 7:55 AM, Greg Flanagan <greg.flanagan at shaw.ca> wrote:
> 
> FYI
> 
> On my boat at least one of the screws holding the sending unit was stripped and the tank leaked at this point when filled. As I access the fuel tank through the fuel gauge sending unit port, I improved this port years ago by putting in a permanent flange made of white plastic lumber. I attached the flange to the tank with small bolts and incorporated stud mounts in the flange that stick up to attach the sending unit. This solves the corrosion problem of SS screws into aluminum. Instead of having to use finicky screws the sending unit now slips on the studs and is secured with nuts. Of course there is a standard gasket between the flange and tank and a second one between the flange and sending unit. Much like an inspection port. I just have to take 5 nuts off and pop the sending unit out. 
> 
> 
> Cheers,
> 
> Greg 
> Hoop Dancer #1076
> 
>> On Aug 16, 2019, at 7:09 AM, Jeff Hare <Catalina at thehares.com> wrote:
>> 
>> Few tips.
>> 
>> - A screwdriver socket or one of those L shaped Philips screwdriver wrenches might be needed to remove the screws. 
>> 
>> - Use a Sharpie to mark the orientation between the fuel sender plate and the fuel tank before you remove it. There are 5 or so screws and all the screws will line up in only 1 orientation. All other orientations will allow some but not all of the screws to fit.
>> 
>> - The Analog "float on the arm" version of the sender is what you have now. The latest tanks come with a tube that senses the fuel level. It's what we have and even though there are no moving parts, I don't like it as much. The reason is that it causes the fuel gauge to move in incremental jumps, so it'll take some time to trust that it's doing the right thing. It may also be more difficult to install with that limited room without removing part of the shelf.
>> 
>> - Before you change out the sender, check the ground and sender wires to be sure that they are in good shape and also run through the gauge diagnostics to be sure it's not the gauge. We had to replace our gauge that stopped working properly. Bought an exact replacement on Amazon as I recall.
>> 
>> -Jeff Hare 
>> #809 2001 Woodbine II
>> 
>> 
>> 
>> -----Original Message-----
>> From: C320-list <c320-list-bounces at lists.catalina320.com> On Behalf Of Charles Martin
>> Sent: Thursday, August 15, 2019 5:13 PM
>> To: C320-list at catalina320.com
>> Subject: [C320-list] Fuel tank sender replacement for 2000 model
>> 
>> Dear Catalina 320 Shipmates:
>> 
>> I need to replace the sender on my 19 gallon fuel tank for our 2000 model C320. Has anyone done this? The fiberglass body juts out over the sender port, so that it looks like it will be hard to remove the sender unit unless I remove the tank first. Any advice?
>> 
>> Best,
>> Chip Martin
>> Sail # 767 -- Bonaventure
>> (410) 231-0199
>> chiprmartin at gmail.com
>>