Fuel Gauge - Does Not Read Below 1/4 Full Tank
Article No.97-26-7
12/22/97
GAUGE - FUEL - DOES NOT READ BELOW 1/4
FORD:
1998 CONTOUR
LINCOLN-MERCURY:
1998 MYSTIQUE
ISSUE:
The fuel gauge may not read above 3/4 tank when tank is full or below 1/4 tank when tank is empty on some vehicles. This may be caused by the inner fuel tank welds causing the float arm to not reach the bottom of the tank.
ACTION:
Replace the fuel tank or fuel pump with a revised fuel tank or fuel pump. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
1. Perform Fuel Gauge System Diagnostics Pinpoint Test B found in the 1998 Contour/Mystique Workshop Manual, Section 413-01. Does Pinpoint Test Step B3 instruct you to replace the fuel pump unit?
^ NO - Do not perform this TSB repair procedure. Instead, continue pinpoint test diagnostics and repair as necessary
^ YES - Perform the diagnostic and repair steps per the following Step 2
2. Remove the fuel pump unit by referring to the Workshop Manual, Section 310-01. Test the fuel pump as follows:
a. Measure resistance between circuits 8-GA7 and 91-GA7 at the fuel pump unit (Figure 1).
b. Note the resistance readings with the float arm against the empty stop and the full stop. Specifications are:
^ Full Stop: Less than 30 Ohms
^ Empty Stop: Greater than 140 Ohms
c. Are resistance values within specifications?
^ YES - Replace fuel tank with revised Fuel Tank (F8RZ-9002-AL) and install a new fuel pump unit and gasket. Refer to the Component Application Chart for correct service part
^ NO - Replace the fuel pump unit and gasket. Find the molded number on the bottom of the fuel tank and select the correct fuel pump unit from the Component Application Chart
NOTE:
USE ONLY THE FUEL PUMP UNIT SPECIFIED IN THE COMPONENT APPLICATION CHART. USE OF ANY OTHER FUEL PUMP UNIT MAY RESULT IN INACCURATE FUEL LEVEL INDICATION.
3. After reassembly, perform the Evaporative Emission System Leak Test as follows:
CAUTION:
THE EVAPORATIVE EMISSION SYSTEM MUST NOT BE PRESSURIZED TO MORE THAN 3.48 kPa (14" H2O) OR DAMAGE TO THE EVAPORATIVE EMISSION SYSTEM MAY OCCUR.
a. Connect the Evaporative Emission System Leak Tester (Rotunda 134-00056).
NOTE:
THE IGNITION SWITCH MUST BE IN THE "KEY ON" AND "ENGINE OFF" POSITION.
NOTE:
BE SURE THE FUEL FILLER CAP IS PROPERLY TORQUED TO THE FIRST "CLICK."
b. Using the New Generation Star (NGS) Tester, apply 12 volts to the canister vent solenoid.
c. Pressurize the evaporative emission system to 3.48 kPa (14" H2O).
d. Monitor the system for 2 minutes. The system tails leak test if the pressure falls below 2.0 kPa (8" H20).
e. Repair any leaks as required.
f. Repeat the leak test of the evaporative emission system until the system remains above 2.0 kPa (8" H20) after the 2 minute test period.
PART NUMBER PART NAME
F8RZ-9H307-BC Fuel Pump
F8RZ-9H307-AB Fuel Pump
F7RZ-9350-BA Fuel Pump
F7RZ-9350-AA Fuel Pump
F8RZ-9276-AA Fuel Pump/Sender Gasket (For Both
2.0L And 2.5L)
F8RZ-9O02-AL Fuel Tank
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
972607A Replace Fuel Tank And 2.1 Hrs.
Pump - Includes
Evaporative Emission
System Leak Test
972607B Replace Fuel Pump Only - 0.8 Hr.
Includes Evaporative
Emission System Leak
Test
DEALER CODING
CONDITION
BASIC PART NO. CODE
9002 14
OASIS CODES: 204000, 204200, 206000, 404000, 607000