Instruments - Fuel Gauge Inaccuracy
NO: 23-30DATE: 5-13-2008
MODEL:
All New S80 (124) AWD only, Model Year 2007-
All New XC70 (136), Model Year 2008-
SUBJECT:
Repair of Inaccurate Fuel Gauge by Rerouting Hoses in Tank
REFERENCE: VIDA
Note!
If using a printed version of this TNN, first check for the latest online version.
THIS TNN SUPERSEDES THE PREVIOUS 23-30 DATED 11-20-07. THE FUEL PUMP INSTALLATION INSTRUCTIONS HAVE BEEN CLARIFIED. PLEASE UPDATE YOUR FILES.
Description:
There may be cases when the fuel gauge is inaccurate. It can be one of the following two scenarios; however, it typically will not be both scenarios on the same vehicle:
a) After filling the tank, the fuel gauge rises to an indication of approximately 1/2 to 3/4 tank, but does not read "full", even though the tank has in fact been filled.
b) As fuel is consumed, the fuel gauge drops normally until it reaches approximately 1/4, after which the indicated fuel level does not change.
In both the above cases, the vehicle operates normally, and no warning messages or DTC's are shown.
Note!
This TNN is not designed to provide diagnosis and repair information in cases of vehicle drivability or DTC's. In those cases, refer to the appropriate section in VIDA.
Service:
The most likely cause for the situations described above is blockage of the sender float on the fuel pump (FP), by a hose or electrical cable inside the tank. The service method below describes how to route the hoses and cables inside the tank so that the sender float is not blocked.
Note!
There is no need to replace the fuel pump or fuel tank when performing this repair. This method should also be used if the fuel pump and/or fuel tank are replaced for any other reasons, for example, if the sender has an electrical fault.
Material
Special Tools
1. Note!
Some variation in the illustrations may occur, but the essential information is always correct.
2. Securing lines
This illustration shows the desired end result: all hoses and cables inside the tank are routed away from the sender float (3 o'clock position on the pump).
This photo illustrates an example of the conflict which occurs if the filter hose extends toward the sender float.
3. Draining fuel tank
Warning!
Risk of explosion. Use fresh air mask.
Warning!
Always follow the fuel extraction equipment's instructions to prevent accidents.
Insert the hose 9512896 with protective pipe 9512908 to protect the spring-loaded flap in the filler pipe.
Connect the hose to a fuel extractor.
Extract the fuel until air comes out.
Start the engine and allow it to idle.
Continue to draw fuel out until the tank is empty.
Turn off the engine.
4. Fuel tank and lines
Warning!
The fuel system remains under pressure for a long time after the ignition has been switched off. The fuel pressure must be released before starting any repairs. Failure to follow the instructions can lead to personal injury.
5. Relieving pressure from the fuel system, pressure reduction
Remove the fuse for the fuel pump (FP).
Start the engine and allow it to idle until it stops.
Turn the engine using the starter motor for approximately 5 seconds until the pressure in the fuel rail has been reduced.
Install the fuel pump fuse.
6. Remove the battery's negative cable, see:
> Removal, replacement and installation
> Electrical system
> Battery and mounting
> Battery
7. Remove the fuel tank, see
> Removal, replacement and installation
> Engine with mountings and equipment
> Fuel system
> Fuel tank, fuel lines, evaporative system
> Fuel tank
8. Removing lines from the fuel tank
When removing the fuel tank, lower the tank 200-300 mm (8 to 12 inches) and disconnect the remaining lines and terminals from the top of the tank.
9. Remove the fuel pump and level sensor unit from the tank, see:
> Removal, replacement and installation
> Engine with mountings and equipment
> Fuel system
> Fuel pump and strainer
> Fuel pump and filter
> Fuel pump and level sensor unit
Note!
Remove the fuel pump assembly only after disconnecting all hoses and connectors as per VIDA.
10. Exposing opening
Carefully insert the entire bunch of hoses and cables back into the tank so that the opening for the fuel pump is exposed.
This is to obtain the best possible access for work in steps 11 and 12.
11. Removal of the fuel line
Unhook the fuel filter's holder (1) and release the hose (2) from the holder.
Reinstall the holder for the fuel filter.
12. Installation of cable tie
Lift up the hose (1) from the fuel filter to the thick black hose and install cable tie 983750 (2) around both the hoses.
It is important to ensure that the filter hose is kept as short as possible between its connection at the filter and the cable tie, in order to keep the hose away from the float.
13. Installing the holder
Note!
Only applies to vehicles without a holder. If the holder is present, ensure that it is installed as per the description below.
Install holder 31261535 above all lines/hoses.
Place the holder as far in on the cable bundle as possible.
Secure the holder's smaller eyelet in the thick black hose as illustrated.
14. Rerouting of hoses
The white hose which attaches to the underside of the pump should be reinstalled so that it is routed clockwise around the pump. A cable tie (blue arrow) should be used to secure the smaller white hose to the larger hose.
It may be easier to release the 2 quick-connects (yellow arrows) and perform this operation on a workbench.
15. Installation
To install, reverse the removal procedure:
Insert lower half of fuel pump into tank.
Reconnect all hoses and cables in reverse order of removal.
Note!
The specification for the amount that the white corrugated hose (along red arrow in photo) should be inserted into the pump is 2" (50 mm). Do not over or under insert the hose.
Before securing the pump to the tank, check with a flashlight to ensure that all hoses remain clear of the sender float. It may also be possible to lift the float with a small screwdriver or hook to ensure that it freely travels its entire span.
Note!
Always use a new rubber seal between the fuel pump and tank.
Note!
When lining up the indicator notches at the top of the pump and on the tank, a small amount of rotation may be possible. Rotate the pump slightly clockwise on installation to help ensure that the float remains free.
WARRANTY CLAIM INFORMATION