After encountering the same results as this chap:-

http://www.landyzone.co.uk/lz/f8/fuel-pump-cutting-out-1-4-tank-258226.html#post3082545

I decided to try and sort this issue today. Earlier in the week, I'd had a discussion with my mate about which way to bend the arm to reposition the float. My initial gut reaction was to bend the float down and my friend was inagreement. However, I got to thinking (overthinking? ) the issue and was unsure; the arm needs to be bent upwards... anyhow after various sketches on the work table, it was agreed the float should be bent down.

Upon removing the fuel pump, I looked and thought, no, the arm needs to be bent upwards. What actually happened when I ran out of fuel is that the gauge was registering 1/4 full - the sender track was giving a false, high, reading.

What I want to happen is for the gauge to read zero, or at least bring the orange light on when there's still some fuel left in the tank. The sender needs to be at the bottom of its track..

I think we'd got the pivot point in relation to the sender track and float muddled up. Here's a diagram of what I did to the pump:-



Taken to extremes, by bending the arm up and repositioning the float higher, one could get the gauge to read zero when there's still half a tank or more of fuel left....

you can do it by measuring the depth of the tank from the top's edge then measure from the top of the pump and adjust the float to be let's say 3 -5 cm higher...simple as that

sierrafery said:

..simple as that

Click to expand...

TRUE FACT! However, I didn't get as far as messing about with a measuring stick & tape measure in the diesel. I did power the pump up outside the tank to make sure than when the sender was at the bottom of the track, the gauge did indeed read zero (it did).
However, interesting to note that there's a hell of a delay built into the system so the needle doesn't bounce around over bumps etc.. It was quicker for me to turn the ignition off then on again to get a reading.