I can provide a little information on this.
Because this car has the saddle style tank there are actually two sending units.
The one on the driver's side assembly contains a return-pressure-driven mechanical pump which pumps fuel from the driver's side of the saddle over to the passenger's side of the saddle. This assembly also has a level sending unit.
The one on the passenger's side contains the main electric pressurizing pump which actually runs the engine. This assembly ALSO has a level sending unit.
The two sending units are wired together so that the average of the two is sent to the instrument cluster.
This exact thing happened to me not that long ago and I could not for the life of me figure out how to get it to work with only one sending unit functioning (for a few hours I thought this would be an acceptable solution, but now I'm glad I've got it working with both units).
I ended up cutting a hole in the floor of the car the same as some folks (including me) have done to get to the main pump on the passenger's side. I pulled the sending unit and drilled out the plastic plug that allows the wires to pass through the metal assembly housing/cap. I ran brand new wires and then sealed it all up using gas tank epoxy found at my local auto parts store.
I did have trouble getting the epoxy to seal around the wires and had to repeat the job several times until I figured out what I was doing wrong - the epoxy hardens too much and doesn't stick to the wire insulation enough. Eventually the wire flexes enough and opens up enough of a gap that the fuel can seep through. I solved this by fitting a couple of pieces of bare 14 gauge copper wire (ground line from household wiring) which the epoxy stuck to brilliantly. I soldered the assembly wires on the inside and soldered the new leads for the signal back to the instrument cluster on the outside. It's been ~3 months now and it hasn't leaked a drop, even with pretty big temperature cycles (it's been down to ~-5C already here).
Of course YMMV but I wanted to share my experience.
--
1998 V70 AWD->FWD Turbo 200k+
|