Instruments - Fuel Gauge Intermittent Erratic Readings
No: 86/07/02/NASRef:
*Issue: 2
Date: 20 December 2004*
Fuel Gauge Level Troubleshooting
Updated information is shown by asterisks and gray shading.
AFFECTED VEHICLE RANGE:
Freelander (LN) ALL
SITUATION:
INTERMITTENT OPERATION OF FUEL GAUGE
The customer may complain of one or more of the following symptoms:
^ Fuel gauge reads zero regardless of fuel level in tank.
^ Gauge shows a constant reading with various levels of fuel level in tank.
^ The fuel gauge consistently indicates inaccurate fuel levels.
RESOLUTION:
INVESTIGATE CAUSE OF ERRATIC READINGS AND REPLACE SENDER UNIT IF INDICATED
The symptoms may result from contamination or continuity interruptions on the sender tile. Where a complaint consistent with any of the symptoms is confirmed, use the procedure in this TIB to ensure correct operation of the fuel gauge sender unit.
PARTS INFORMATION:
CAUTION:
After VIN 2A209859 a new style "MAPPS" sender unit is used in conjunction with a revised fuel pump assembly and a larger gas tank. The new pump and fuel sender ARE NOT COMPATIBLE with the smaller fuel tanks or the instrument cluster assembly used before VIN 2A209858. Refer to Alert PA02GI-17 for additional details.
NOTE:
Sender-related problems can be repaired by replacing the sender only. Replacement of the complete fuel pump assembly is NOT required for correction of sender-related symptoms.
*DDW WARRANTY CLAIMS:
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.*
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
TROUBLESHOOT INACCURATE FUEL LEVELS
1. If the fuel gauge consistently indicates inaccurate fuel levels, refer to RAVE Workshop Manual section 19.45.08 and remove the fuel pump assembly.
2. Inspect the pump assembly for external damage, such as distorted sender unit float arm.
3. If no visual defects can be seen, disconnect the two fuel gauge sender connectors from the top of the pump assembly. (Arrowed in Figure 1)
4. Place the pump assembly upright on a clean level surface.
5. Set a Digital multi-meter (DMM) to measure resistance and connect to the sender electrical connectors.
6. Measure the distance from the surface to the center of the float arm at rest (Dimension "A" in Figure 1) and record the measurement.
7. With the float arm still in the rest position, record the resistance at the sender connectors.
8. With the meter still connected, raise the float arm slowly toward its highest position, and monitor the meter for a smooth fall in resistance.
9. If the meter registers an open circuit at any point in the float arm travel, discontinue testing and go to Install New Replacement Sender section below.
10. With the float arm at dimension "B" in Figure 1, record float height and resistance measurements.
11. Refer to the table and verify that recorded float height and resistance measurements are within parameters shown.
12. If float is slightly outside tolerances carefully bend the float arm to adjust to the correct height position.
13. If adjustments are made, repeat the test sequence to verify correct measurements and resistance
14. If the measured resistance remains outside the specified range go to the replacement section.
15. If sender passes all tests, install the original fuel pump assembly to the tank using a new sealing ring (ESR3806) and investigate alternative causes for the problem.
INSTALL NEW REPLACEMENT SENDER
*1. If any of the following conditions apply, refer to GTR Workshop Manual, section 88.25.32 and replace the sender unit (YAD000070 or YAD000080):*
^ If the fuel gauge reads zero regardless of fuel level.
^ If the fuel gauge shows a constant reading regardless of fuel level.
^ If the sender showed an open circuit in the test above.
^ If the measured resistance remains outside of the resistance parameters in the test above.
2. Install the repaired fuel pump assembly to the tank using a new sealing ring (ESR3806).