Instruments - Erratic Fuel Gauge Readings
XJ310-01DATE
04/04
XJ range
MODEL
2004 MY
XJ range NA
VIN
G00421-G28859
Erratic Fuel Gauge Reading -
Fuel Tank Sender -
Repair Procedure
Issue:
On some 2004 MY XJ range normally aspirated vehicles within the above VIN range, customers may express concern that the fuel gauge fluctuates, reads erratically or that the low fuel light is on soon after filling the fuel tank. This bulletin outlines a process to determine if there is a fault with the fuel tank sender.
Action:
In case of a verified customer complaint of the above condition on a 2004 MY XJ range vehicle within the above VIN range, follow the workshop procedure outlined below.
WORKSHOP PROCEDURE
1. Open driver's door.
2. Use Worldwide Diagnostic System (WDS) to check for DTCs B1202, B1204, B2627, B2628 stored in the instrument cluster.
Note:
If any of these DTCs are stored, carry out the associated diagnostic routine and claim as a separate Warranty Claim. Then clear DTCs using WDS.
3. Place instrument cluster into test mode as follows: Press trip button in and hold, turn the ignition "ON", release the trip button between five and eight seconds after ignition is switched "ON".
4. Scroll to RAW1 signal displayed on message center by repeatedly pressing the trip button.
5. Rock vehicle and view reading. A variation in the reading should be seen.
Note:
A good reading should be between 27 and 240. If 255 is displayed at any time this indicates an open circuit.
6. Scroll to RAW2 signal displayed on message center by pressing the trip button.
7. Rock vehicle and view reading. A variation in the reading should be seen.
Note:
A good reading should be between 27 and 240. If 255 is displayed at any time this indicates an open circuit.
8. If readouts shows faulty sensor, replace both the fuel pump module and the fuel transfer pump to bring the vehicle to the latest specification.
If readouts are as expected, remove fuel pump module and fuel transfer pump. Refer to see Workshop Manual, section: 310-01, SRO 19.45.08 and 19.45.21.
10. Place fuel pump module on a clean workbench.
11. Attach a suitable Digital Multi Meter (DMM) (set DMM to resistance/continuity) to sender unit pins.
Note:
Utilize adaptors J1006 from the WDS adaptor kit 3548-1358-00 to reduce the possibility of damage to the pins.
12. Slowly sweep the float arm across the full range of the sender to check for open circuit.
Note:
The readout should gradually increase from 15 ohms to 160 ohms. If high resistance is displayed at any time this indicates an open circuit.
13. Place the fuel transfer pump on to a clean workbench.
14. Attach a suitable DMM (set DMM to resistance/continuity) to sender unit pins.
Note:
Utilize adaptors J1006 from the WDS adaptor kit 3548-1358-001 to reduce the possibility of damage to the pins.
15. Slowly sweep the float arm across the full range of the sender to check for open circuit.
Note:
The readout should gradually increase from 15 ohms to 160 ohms. If high resistance is displayed at any time this indicates an open circuit.
16. If there is a fault with the sender track resistance, replace both the fuel pump module and the fuel transfer pump to bring the vehicle to the latest specification. If the track resistance is OK, reinstall the fuel pump module and fuel transfer pump, and ensure that there is a good connection at the electrical connections. Refer to see Workshop Manual, section: 310-01, SRO 19.45.08 and 19.45.21.
17. Close drivers door.
Parts Information:
Warranty Information:
Warranty claims should be submitted quoting the information found in the table.
This will result in payment of the stated time and, where applicable parts/miscellaneous expense codes as listed.
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