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  2003 160 DAUNTLESS Fuel Tank Level Sender

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Author Topic:   2003 160 DAUNTLESS Fuel Tank Level Sender
shossa posted 03-31-2013 03:48 PM ET (US)   Profile for shossa   Send Email to shossa  
Where on a 2003 Boston Whaler 160 DAUNTLESS can the fuel tank level sender be accessed?
Jefecinco posted 03-31-2013 06:46 PM ET (US)     Profile for Jefecinco  Send Email to Jefecinco     
Try removing the hatch in the engine well. Stick your head in there and I believe you will see the sending unit a few inches from the rear of the fuel tank.

Butch

jimh posted 03-31-2013 10:10 PM ET (US)     Profile for jimh  Send Email to jimh     
For any recent model Boston Whaler boat you can find detailed assembly drawings that show all components like a fuel tank level sender. Visit

whalerparts.com

and select your model year, then your model, then the length of your boat. Then browse the drawings available. You will find a drawing like

http://whalerparts.com/Diagrams/2003/160%20Dauntless/PB160DA04-Model.pdf

that shows the mechanical layout of major components. You will also find a drawing like

http://whalerparts.com/Diagrams/2003/160%20Dauntless/PB160DA05-Model.pdf

that shows more details. Newer models also usually have very detailed electrical drawings.

shossa posted 04-01-2013 01:51 PM ET (US)     Profile for shossa  Send Email to shossa     
butch, jim,

thx both for your quick responses.

@butch, i opened up the hatch and took a look. seems like it isn't there - there's the fill line coming in on the left and the main fuel line going out on the right. see img below.

http://i1294.photobucket.com/albums/b602/shossa/FBD750CB-F49E-45D0-84FA-49DD6E4BCC12-17933-00000CBF951DEFF1_zps4546257b.jpg

@jim, thanks for the links. i've taken a close look at these in the past and couldn't locate the sending unit. for some reason they didn't add that to the diagrams.

my guess is that it's under the console. just wanted to run it by you before i start digging out my batteries.

thx again.
-sam

fishgutz posted 04-02-2013 07:47 AM ET (US)     Profile for fishgutz  Send Email to fishgutz     
Check under your reversible pilot seat. The fuel tank on a Dauntless 16 has 3 different locations for a sending unit (I'm pretty sure). I'll bet if it isn't in the back like in your picture then it is probably under the seat. You'll probably find one or two cutouts under that seat or another inspection port.
I have a Dauntless 14 and here is the pic of the sending unit from the inspection port in the splashwell. http://s42.photobucket.com/user/Fishgutz/media/Boat%20Tech%20Pics/ Fuelsender2.jpg.html?sort=4&o=14 There is also a location for the sending unit under my seat (under the livewell). There are 2 cutouts under my seat mostly for the livewell. If you have a livewell, it should just pull up to expose what is under there.
Jefecinco posted 04-02-2013 07:55 AM ET (US)     Profile for Jefecinco  Send Email to Jefecinco     
Sam,

Sorry for the bum steer. I think Fish.. may be onto something. Check under the seat for access.

Butch

jimh posted 04-02-2013 09:14 AM ET (US)     Profile for jimh  Send Email to jimh     
The typical locations on a fuel tank for fittings on a small boat are as follows: the fuel pick-up is at the aft end; the fuel fill inlet is usually near the forward end; the fuel level sender is usually somewhere in the forward end, too; the vent is almost always at the forward end.

In the detailed drawing (linked above) I can see the location of the fuel fill inlet at the extreme aft end of the tank, in the narrow portion. The vent is clearly shown and is in the forward portion. The fuel pick-up appears to be at the extreme aft, in the narrow portion. Adjacent to the fuel pick-up there is an unidentified circular fitting. That could be the fuel tank level sender.

Also, there are two circular details shown on the fuel tank in the middle portion. One of those seems to be aligned with a circular access plate in the deck, shown as call-out 52 in the drawing (upper left). Remove that circular deck access plate and see what is below it. The fuel tank level sender may be there. It would make a great deal of sense for that to be the case. It would be unusual for Boston Whaler to make a boat and install a component like a fuel tank level sender in a position where half the boat has to be disassembled to gain access.

shossa posted 04-02-2013 11:19 AM ET (US)     Profile for shossa  Send Email to shossa     
yup that makes sense. i'll try to get to that access port under the rps this weekend and let y'all know what i find.

thx for the help.

shossa posted 05-06-2013 05:28 PM ET (US)     Profile for shossa  Send Email to shossa     
I was finally able to work on the boat today. Pulled up the rps and found a hatch leading right to the sending unit.

http://s1294.photobucket.com/user/shossa/media D6C04649-55B8-42B4-A6AE-7ADBA79E3517-964-000000A78A1221B8_zps4b50b3ba.jpg.html

Snapped a pic of it. 6x8mm fasteners securing it to the tank. Was able to get it out and verify that moving the float doesn't cause any movement on the gauge. So now it looks like I've isolated the problem to a faulty sending unit or a short somewhere in the circuit.

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