Instruments - Erratic Fuel Gauge Operation

Date: April 2, 2002

Order No.: P-B-47.10/25

Supersedes:

Group: 47

SUBJECT:
Model 203, Model Year 2001 and Later

Fuel Gauge Complaints, Correct Fuel Sending Unit Part Numbers

If you encounter instances of fuel gauge complaints on Model 203 vehicles, and DAS identifies a malfunctioning sending unit(s), the correct sending unit(s) must be installed.

Magnetic Passive Position Sensor (MAPPS) fuel sending units entered production for all 203 models approximately October 1, 2001. This was as of VIN end numbers A252580 and F182331.





The MAPPS sending units can be identified by a 5-pole plug (figure 1 and 2) on the outside of the mounting plate (left fuel sending unit). The previous fuel sending unit, a thick film resistor style, has a 4-pole plug (figure 3 and 4) on the outside of the mounting plate (left fuel sending unit).

The signal and version coding for both the Instrument Cluster (KI) and the rear SAM must match the fuel sending unit design.

To verify instrument cluster coding (and correct if necessary), follow this procedure.

Select the correct model
Select Control units
Select Information and communication
Select 1CM - instrument cluster with maintenance interval display
Select Control unit adaptations
Select Version coding
Select Fuel tank sensor (NOTE: This choice is not available on early instrument clusters)
Choose either MAPPS for MAPPS fsu or Dickschicht for thick film fsu
Hit F3 to select the displayed version fuel tank sensor
Exit DAS

To verify rear SAM coding (and correct if necessary), follow this procedure.

Select the correct model
Select Control Units
Select Body
Select REAR SAM - rear signal acquisition and actuation module
Select Control unit adaptations
Select Read coding and change if necessary
Select Fuel tank sensor (NOTE: This choice is not available on early rear SAMs)
Choose either New fuel tank sensor (MAPPS) or Old fuel tank sensor ( )
Hit F3 to select the displayed version fuel tank sensor
Exit DAS

Note:
Vehicles equipped with thick film sending units should only have thick film sending units used for repairs. Vehicles equipped with MAPPS sending units should only have MAPPS sending units used for repairs. Do not attempt to retrofit vehicles with fuel sending units of a type other than the original factory installed sending units.

See also EPC info. bulletin E1B47T003 (March 13, 2002) on Netstar Newschannel (Parts Tech Area).





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