Fuel Gauge - Inaccurate reading

89amcjeep06

Models

1986-89 XJ Body


Subject

Incorrect Fuel Level Reading Excessive Fuel Reserve


Index

FUEL SYSTEM


Date August 28, 1989


No.

14-52-89

(C14-04-9) P-3224
BODY CODE LEGEND

XJ - CHEROKEE/WAGONEER (RWD, 4WD)


SYMPTOM/CONDITION

Inaccurate fuel gauge reading, fuel tank will not accept the quantity of fuel according to its rated capacity, or an excessive amount of fuel reserve remaining in fuel tank when gauge reading is "empty". These conditions may be caused by an incorrectly calibrated fuel sender unit.

DIAGNOSIS

Prior to replacing the fuel sender unit, verify that the condition is not caused by an inaccurate fuel gauge or faulty wiring (refer to appropriate Electrical Troubleshooting Manual). Verify that the vehicle is equipped with the correct size fuel tank and the proper sender unit for the tank size. If the above is found to be correct, proceed with the following repair procedure.

PARTS REQUIRED

1 Fuel Sender Unit -
2.5L with 13.5 gal. tank P/N 05252048
2.5L with 20.2 gal. tank P/N 83506281
4.0L with 13.5 gal. tank P/N 83506283
4.0L with 20.2 gal. tank P/N 83506282

REPAIR PROCEDURE

This Repair Procedure involves the removal and replacement of the fuel tank sender unit.

1. Remove fuel filler cap. Drain fuel tank with a portable gasoline siphon/storage tank until the fuel level on vehicle fuel gauge is below one-half full.
2. On vehicles equipped with 4.0L engine, perform MPI Fuel Pressure Release Procedure as outlined in the 1989 Jeep Service Manual (Publication # 81-370-9045) page 14-95.

3. Disconnect battery negative cable.

4. Raise and support the vehicle.

5. Disconnect the fuel vent supply and return hoses from the fuel sender unit.

6. Disconnect the fuel sender unit electrical harness from the main harness.

7. Using a brass punch and hammer, remove fuel sender lock ring by carefully tapping it counter clockwise.

8. Remove the fuel sender unit and the O-ring seal.


NOTE: MAKE CERTAIN THAT THE RUBBER STOPPER ON THE END OF THE FUEL RETURN LINE CAME WITH THE FUEL SENDING UNIT DURING FUEL SENDER REMOVAL. IF NOT, REMOVE IT FROM THE FUEL TANK NOW.


9. Transfer the fuel pump, inlet filter and rubber stopper from the old fuel sender unit to the new fuel sender unit.

10. Install the new fuel sender and new O-ring to the fuel tank. The rubber stopper on the end of the fuel return tube of the sender must be inserted into the fuel tank reservoir cup.


NOTE: EXCESSIVE FUEL PUMP NOISE WILL OCCUR IF THE RUBBER STOPPER ON THE END OF THE FUEL RETURN LINE IS LEFT OFF OR NOT PROPERLY SEATED INTO THE FUEL TANK RESERVOIR CUP.


11. Install the lock ring making certain that the O-ring is properly seated. Carefully tap lock ring clockwise until it seats against stop on fuel tank.

12. Connect the fuel supply and return hoses. Connect the electrical harness.

13. Lower the vehicle and fill fuel tank, and install the fuel filler cap.

14. Connect the battery negative cable.

15. Start the vehicle and inspect for leaks.
POLICY: Reimbursable within the provisions of the warranty.


TIME ALLOWANCE:
Labor Operation No. 08-45-30-91 . . . . . . . . . . . . . . . 0.6 Hrs.


FAILURE CODE: 58 - Internal Defect