Instruments - Fuel Gauge Inaccurate

Classification:
EL99-011

Reference:
NTB99-064

Date:
September 21, 1999

1998-99 FRONTIER FUEL GAUGE INACCURATE

APPLIED VEHICLE:
1998-99 Frontier (D22)

APPLIED DATE:
See note under Service Information

APPLIED ENGINE #:
KA24DE only

SERVICE INFORMATION

If the fuel gauge on a 1998-99 Frontier exhibits the symptoms listed below (indicated by bullet points), the cause may be wire harness to body ground contact points, the fuel sender (in the fuel tank) or the unified control meter (contained in the speedometer assembly).

NOTE:
The wire harness to body ground and fuel sender conditions only apply to vehicles built before September 1, 1999. The unified control meter condition only applies to vehicles built before January 1, 1999.

^ Fuel gauge indicates less than full after the fuel tank is filled.

^ Fuel gauge moves down rapidly to 7/8 or 3/4 after the fuel tank is filled.

Use the following service procedure to repair the vehicle if these incidents occur.

SERVICE PROCEDURE

1. Confirm the incidents occur as described above.

A. If the incidents occur, proceed with step 2.
B. If the incidents do not occur, this bulletin does not apply.





2. Remove the machine bolt from body ground M68 (located behind the passenger side kick panel) and clean the contact surfaces of the ground wire eyelet and the body panel as necessary to ensure metal-to-metal contact (see Figure 1). Reinstall the bolt carefully to avoid damaging the threads.

NOTE:
Do not over-tighten the machine bolt when reinstalling it.





3. Remove the self-tapping screw from body ground M14 (located behind the driver's side kick panel) and clean the contact surfaces of the ground wire eyelet and body panel as necessary to ensure metal-to-metal contact (see Figure 2). Reinstall the screw carefully to avoid damaging the threads.

NOTE:
If the body threads are stripped, install a slightly larger self-tapping screw to secure the body ground wire eyelet.

4. Replace the fuel sender located in the fuel tank.

NOTE:
The fuel sending unit can be accessed by either removing the fuel tank from the bottom of the vehicle or removing the truck bed from the top of the vehicle. Before removing the bed, make sure there is sufficient space around the vehicle to safely remove and store the bed. If the fuel tank is removed, refer to the FE section in the appropriate service manual for instruction on removing the fuel tank/fuel sender.

NOTE:
The following step (step # 5) only applies to vehicles built before January 1, 1999.

5. Replace the speedometer assembly*. Refer to the BT section in the appropriate service manual.

* The speedometer assembly includes the unified control meter, which controls the fuel gauge, speedometer, engine temperature gauge, odometer and tachometer (it equipped).

NOTE:
Conform to local laws regarding speedometer/odometer replacement. A new speedometer/unified control meter with the odometer set to the correct mileage may be ordered as described in Claims Bulletin WB/98-017.





PARTS INFORMATION

NOTE:
The speedometer assemblies listed above must be ordered as described in Claims Bulletin WB/98-017.





CLAIMS INFORMATION
If only the ground wire connections are cleaned and the sending unit replaced, submit a Primary Failed Part (PP) line using the claims coding as shown.





If the ground wire connections are cleaned and the sending unit and speedometer assembly (unified control meter) are replaced, submit a Primary Failed Part (PP) line using the claims coding as shown.