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Osculati code: 27.160.00

I gladly tested the sensor of the 27.160.00 kit as I found myself having to replace the old sensor in the second diesel tank, which was a capacitive one.

The Osculati sensor I tested is a resistive-type tilt bar sensor.  As I prefer “to share the risk” if I have the chance to, so the opportunity that presented itself was the right one to test two different measurement technologies.

When buying the sensor, pay special attention to the height of the rail bar on which the tilt float rests, as Osculati provides it in different heights to be chosen according to the tank depth. Choose the right one for you taking into account an acceptable margin of error.

Moreover, remember to check, just in case, the round flange on the tank, although the standard version is aligned to the classic 5-hole one (SAE-5), just as that at issue, and you should not face any trouble. Once performed the necessary checks, installation is really simple as the instructions provided are complete also as for the electrical connection.

What is most important is to cut to measure the tilt bar, that is the float bar providing the required information concerning the fuel level to the system. Before ending the installation, place both the tilt bar and the float into the tank and check that the bar travel is not hindered by the tank walls, then cut the bar to measure.

The importance of the preparatory stage cannot be underestimated, as, once the device is closed and tight, it would be difficult to make further modifications. Installation can be performed also when the tank is half-full (actually it is even better because bar travel and operation can be tested under real conditions). However, to make changes and open plugs often, having traces of old sealant, have its downsides and can be dangerous, as the old gasket and dirt may fall inside the tank, causing potential outlet clogging. Therefore, it is better to perform the installation when there is no fuel in the tank, thus giving you the opportunity to remove oil deposit, if any.

To test the sensor, plug it and move the bar manually.

On my tank, the sensor flange is fitted onto the inspection cap, therefore I could install the rail bar and the float rod comfortably on a table and even choosing to seal everything properly before closing the cap. Unfortunately the receiving bore wasn’t wide enough to let me install the sensor bar as such. The problem was resolved by unscrewing the fixing screw of the rail for the fine adjustment of the telescopic part that, actually, can be almost completely disassembled, then by inserting the bar in the plug and finally by assembling the component parts.

Takeaways: the kit is complete in all its parts, including a dashboard dial whose inner body diameter is compatible with several others such as classical VDOs (shouldn’t it fit perfectly remove a few microns from its seat using sandpaper). The price-performance ratio is excellent and the system works perfectly and precisely considering its specificities and minimal differences with respect to the second sensor you might want to keep. 


Giampaolo Gentili
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