Fuel System - Fuel Gauge/Tank Fault Tracing Guide
Title Fuel gauge / tank fault tracing guide and Prior ApprovalRef No US20532.1.5 en-GB
Issuer -
Partner 3 US 7510 Volvo Cars North America
Func Group 2331
Func Desc fuel pump; feed pump
Status Released
Status Date 02-09-2012
Issue Date 08-23-2011
Reference VIDA, VSTG, CPI 04-2011, SMB 23-038
Attachment
Vehicle Type
CSC Customer Symptom Codes
DTC Diagnostic Trouble Codes Text
Text
CSC = Customer Symptom Code
DTC = Diagnostic Trouble Code
Note!
If using a printed copy of this Technical Journal, first check for the latest online version.
NOTE!
THIS DOCUMENT SUPERSEDES THE PREVIOUS TECHNICAL JOURNAL 20532 DATED 04-05- 2011. The fault tracing information has changed. Product modifications for AWD vehicles have been added. The fuel pump/tank prior approval will now work through VRC2. PLEASE UPDATE YOUR FILES.
DESCRIPTION:
Volvo Cars of North America is continuing its prior approval process for any claims submitted for the replacement of a fuel pump and/or fuel tank on XC60 (10-) and XC70 (08-). However, this TJ has information and a fault tracing guide for ALL vehicles listed in the TJ header.
Claims for repairs on XC70 (08-) and XC60 (10-) including a fuel tank and/or fuel pump require a Prior Approval Department authorization code.
Beginning February 13th, 2012, Volvo Cars of North America will discontinue the use of the old process of calling an agent on the phone and reviewing the data, instead, use the new Prior Approval application found on VRC2.
An authorization code for a fuel pump and/or fuel tank will only be available via the Prior Approval Dept. The technician should use the Prior Approval application on VRC2. To find this application, log into VRC2, choose the Service tab, choose Technical on the left side of the screen, and then choose Prior Approvals. This TJ will explain the prior approval process required for submission of any claim for the replacement of a pump and/or tank.
Technicians who think they need to replace a fuel pump and/or fuel tank to make a repair on an XC70 (08-) or XC60 (10-) should use the Prior Approval application before installing the fuel pump and/or fuel tank and have the information detailed in the Diagnostic sheet ready to be transferred to the Prior Approval application.
This is not a parts restriction process. Parts availability questions should be directed to the Parts Retailer Services Department.
Many parts have been unnecessarily replaced in the past. This TJ contains fault tracing information mainly for fuel gauge problems. However, customers may contact the workshop for a stalled engine or a no start symptom. In these cases it is unknown if it is a fuel pressure problem or incorrect fuel level indication that caused the stall/no start condition. Therefore, this TJ will provide a high level fault tracing guide that was created in order to direct the technician down the correct fault tracing and repair path.
The major fuel gauge faults seen on Front Wheel Drive (FWD) vehicles can be divided into 3 categories:
1: Pump level sender unit malfunction.
2: Pump float arm stuck at top position
3: Not possible to fill up to a full tank
The attached document for FWD vehicles is divided in three chapters:
Chapter 1 Fault tracing
Chapter 2 (unused for FWD)
Chapter 3 Translation table- ohm to liters/gallons and miscellaneous information
Chapter 4 Diagnostic sheet that needs to be filled if contacting technical helpdesk
The major fuel gauge faults seen on All Wheel Drive (AWD) vehicles can be divided into the following categories:
Wrong fuel level indication, passive (ejector) side:
1: Float separated from fuel sender arm.
2: Level sender arm assy. separated from bracket.
3: Level sender arm hooked on wire.
4: Kinked hose inside carrier.
5: Kinked hose inside pot. (Noise and pressure pulsations as well)
6: Kinked hose in general.
7: Broken venturi.
Wrong fuel level indication, active (pump) side:
8: Level sender arm separated from pump.
9: Level sender arm hooked on wire or hose.
10: Kinked hoses
The attached document for AWD vehicles is divided in four chapters:
Chapter 1 Fault tracing
Chapter 2 How to assemble a pump with new design (with return hose stop) in an old tank
Chapter 3 Translation table- ohm to liters/gallons and miscellaneous information
Chapter 4 Diagnostic sheet that needs to be filled if contacting technical helpdesk
In order to aid in fault tracing, a video has been created and is posted on the link below. Please view this view before fault tracing a fuel pressure and/or fuel gauge complaint.
Go to PDF viewing library, TJ attachments to view video:
SERVICE:
For all vehicles: Follow the fault tracing guide in the appropriate attachment.
PRODUCT MODIFICATION (AWD only). Match the item number in description above.
1: Stamping and washer process at supplier, secured 08W23, Chassis number 124 90292, 135 72723, 136 50609
2: Bracket on the carrier* reinforced 09W09, but old parts to be used up, Chassis number, 124 103585, 135 10231, 136 62859, 156 18836
3: Sleeve around electrical cable, hose from remote jet pump feed & return and filter introduced , 09w09, Chassis number 124 103585, 135 10231, 136 62859, 156 18836
4: Manual process changed at supplier and X-ray equipment introduced 08W50, Chassis number 124 102631, 135 97671, 136 61879, 15612060
5: Physical stop in the pot introduced 08W44. Chassis number, 124 99887, 135 92223, 136 60236, 156 6378
6: Process at supplier secured 08W32, Chassis number, 124 95242, 135 80707, 136 55376
7: New clipping feature introduced 08W32, Chassis number, 124 95242, 135 80707, 136 55376
8: Introduced 2 extra tie wraps 08W44, Chassis number, 124 99887, 135 92223, 136 60236, 156 6378
9-10: X-ray equipment introduced 08W50, Chassis number, 124 99887, 135 92223, 136 60236 136 12060
Feed, return line and electrical cable harness reduced with 110mm. 08W39, Chassis number 124 98473, 135 87366, 136 58612, 156 1421
Tube from pump to life time filter reduced with 60 mm. 08W39, Chassis number, 124 98473, 135 87366, 136 58612, 156 1431
* Carrier Plastic part inside the fuel tank, to hold the ~internals~ in place
VOLVO STANDARD TIMES GUIDE (VSTG) INFO:
Operation number 28468 - Engine control module, fault tracing DTC - See VSTG Operation number 23811* - Fuel pressure/residual pressure check - See VSTG
* Note this op code should be used ONCE for the fuel tank draining procedure and for the pressure check.
Do not use with Operation Number 23341!
Operation number 23428 - Fuel tank install/remove/replace (excludes draining) - See VSTG
Operation number 23341 - Fuel pump replace (includes fuel system de-pressurization, fuel tank draining/filling) - See VSTG
- Claims may be submitted under the new car warranty when there is a documented customer complaint using claim type: 01
- Labor times are valid at the time of release and are subject to change.
To view TJ attachments: