Dear hohenstauffen,

May this find you well. I may be able to help with part of this. Let's start with the fuel pump. The fuel gauge receives signals from the tank unit, via the brown and green-white wires. The other two wires - pink and black - power the fuel pump.

Thus, if the brown wire has been broken, the fuel gauge will not get a signal. It is not likely that you pulled loose the brown wire, because it is soldered into a brass tube, that goes through the black plastic cap. The brown wire, that runs from the brass tube on the underside of the cap, to the send unit. is also soldered to the brass tube.

To determine whether the brown wire's continuity has been broken, wiggle the wire, to see if doing that revives the gauge. If it does, then the wire has been pulled loose and needs to be reconnected. Using a round-tip knife, you can dig-out the sealant around the wires, where they go through the black plastic fuel tank cap. You can replace the sealant with: (a) hot melt adhesive or (b) an epoxy glue. These materials, being liquids, will form an airtight-seal around the wires.

If the brown wire has been pulled loose, you'll ned to remove the send unit from the car, before you re-solder the wire. Bringing a source of strong radiant heat near a gas tank should be avoided. Once you have the send unit out of the car, use a Volt-Ohm-Multimeter to check for continuity on all wires.

It is also possible, that when you reinstalled the tank unit after replacing the fuel pump, that you did not seat it properly. While the float, from which originates the signal to the fuel gauge, is inside the plastic tube, the float may not move freely if the tube is installed at an angle. See the FAQs for guidance on how to remove/re-install a tank unit.

The in-tank fuel hose - from the metal tube on the underside of the black cap to the fuel pump - should be mounted so the hose is right against the side of the send unit.

Hope some of this is helpful.

Yours faithfully,

spook