Date: Fri, 13 Jun 1997 18:52:09 +0300 (EET)
From: "Kostas G. D. Chryssos Ph.D." (sv1bt@compulink.gr)
Subject: Re: 3sgte owners
Cc: mr2-interest@validgh.com

>Has anyone installed a fuel gauge? I just bought an electronic one and  I'd
>like to know the best way to attach sending unit to fuel rail.
>
>Chuck A
>91mr2T

Well I will tell you how I did. When I tried a NOS system on my 91T I had to
install a fuel pressure switch,  which is not much different, a switch unit
instead of a sender unit (almost same dimensions, mounting etc).
So this is how I did it:

1) Take a spare bolt like the one used on the fuel filter to hold the top banjo.

2) Drill the top of this bolt and enlarge the hole just enough to apply
threads inside the hole, make sure the first drilling goes all the way into
the hollow part of the bolt, where the fuel runs.

3) Get an adapter with external threads to fit the threaded hole you just
did on one side and to fit your sender on the other side.

4) Mount the sender to this adapter properly (use proper squize flange etc)
and then mount the adapter to the bolt again properly.

5) Remove the top bolt from the fuel filter, install new squize flanges and
install the sender/adaptor/bolt configuration instead.

6) Tighten properly and turn the ignition key without starting the engine
(just keep the fuel pump running) and check for leaks.

7) If no leaks, start engine and rev to 5000 to get fuel pump run at
hi-speed and recheck for leaks. Checking for leaks should be done with a
colored ( Deep Blue is best) paper napkin held around the installed bolt.
Quickly remove napkin and visually check for  any color change drops...if
not any then sniff too....if no gas smell then there is no leaks. Stains of
gas sniffed means leaks which are bad and should be corrected.

Note: The above is only a description of how I did it and by no means this
should be considered as a recommendation to anyone.
Any modification on the fuel delivery system of your car is considered
illegal in many countries. Parts connected to the fuel delivery system MUST
be approved and be qualified for the intended use.

Kostas G.D.Chryssos Ph.D.
ELFON Ltd. 30 Ikarias str., Glyfada GR 16675 Athens HELLAS (GREECE)
Tel: + 301 9628212 Fax: + 301 9628539
e-mail: sv1bt@otenet.gr - sv1bt@compulink.gr