Jon began work on our 1993 Ford Escort XR3i by draining the fuel tank using the in-tank pump, powered through fuse 5, to empty the contents. Once drained, the fuel tank was removed along with the sender and pump assembly. A new sender unit was installed; although slightly different in appearance, it was found to be suitably compatible. Jon confirmed that the wiring matched the original unit, plugged it in, and carried out a successful function test.
He then cut and shaped 8mm copper fuel pipe to create two new lines from the replacement pump and sender unit to match the car’s existing pipework. With the sender and pump fitted to the tank, the assembly was refitted to the vehicle. All associated connections were made, and 20 litres of fuel were added to test the gauge, which now displayed correctly. A further 20 litres were added, confirming the gauge showed a full reading.
Jon ran the engine to check for fuel leaks, with no issues found. The heat shields were refitted, and the exhaust system was remounted. The rear seat was reinstalled and the work area cleaned. He also wiped down the offside rear shock absorber and applied sealant to a minor blow at the centre box of the exhaust.
A road test confirmed all systems were functioning correctly, and the car was taken across for its MOT retest. Before beginning the formal check, the MOT team placed the car on the exhaust gas analyser to verify emissions. However, the lambda reading could not be brought within specification. Jon returned the car to the workshop, allowing it to cool before preparing to remove and clean the oxygen sensors for further
