Fuel System - Fuel Gauge Doesn't Display Full After Fueling
20 12 05December 13, 2012
2028931
Vehicle Information
Condition
Fuel Gauge does not Display Full after Refueling
Technical Background
Diesel fuel may foam in the fuel tank when rapidly filling from empty, and there is not enough space in the tank for the foam to expand. This causes the fuel nozzle to shut off prematurely. When filling the tank at a slower rate, it is possible to fill the tank completely.
Production Solution
Improved fuel tank design as of VIN: A3_CC025449.
Service
Tip:
When refilling a diesel fuel tank from empty, It is a normal characteristic for the fuel gauge to not display full until the fuel nozzle has shut OFF twice.
Note:
When filling the tank and checking the fuel gauge reading, the vehicle must be on a level surface.
Make sure the diesel fuel will not be contaminated by dirt or gasoline. ONLY store the customers fuel in a clean and approved storage container to avoid cross contamination.
Procedure:
1. Is the fuel gauge displaying all the way full?
YES: This bulletin does not apply, return vehicle to customer.
NO: Review Fuel Supply System Safety Precautions and Clean Working Conditions see Repair Manual group 20 in ElsaWeb, and continue.
2. Remove the rear bench seat to access fuel delivery module, see Repair Group 72 in ElsaWeb.
^ Inspect all wiring harness connections to verify they are fully seated and secured.
^ Are all connections fully seated and secure?
YES: Proceed to step 3.
No: Secure all connections and recheck fuel gauge full operation.
^ Fuel gauge now operating properly?
YES: No further action required.
NO: Proceed to step 3.
3. Remove fuel delivery module and inspect the fuel level sender electrical and mechanical connections, see Repair Group 20 in ElsaWeb.
^ Are the fuel delivery module electrical connections and mechanical connections operating properly?
^ Fuel level sensor -G- fully clipped to fuel supply module.
^ Internal supply module connector fully seated.
YES: Proceed to Fuel Level Sensor -G- Testing.
NO: Reseat fuel level sensor and/or supply module connector.
^ Fuel gauge now operating properly?
YES: No further action required.
NO: Proceed to Fuel Level Sensor -G- Testing.
Fuel Level Sensor -G- Module Testing
Note
Position the fuel delivery module on a clean and flat surface.
^ Hang float arm over an edge (float in full down travel).
^ Measure the resistance between module pin terminals 2 and 3.
Is resistance measurement 290�0.5
ohms?
Yes: Proceed to next step.
No: Replace fuel level sender module.
^ Raise the float arm up to the physical limit and measure the
resistance between module pin terminals 2 and 3.
Is resistance measurement 50 +/- 0.5 ohms?
Yes: Drain and remove diesel fuel tank, install new diesel fuel tank part number 561201055H, use fuel pump from original fuel tank, and refill.
No: Replace fuel level sensor -G- module.
Tip:
Be sure to purge any air from the fuel system before starting engine. See Repair Manual group 23 in ElsaWeb.
Warranty
Required Parts and Tools
Additional Information
All part and service references provided in this Technical Bulletin are subject to change and/or removal.
Always check with your Parts Dept. and Repair Manuals for the latest information.