Fuel Gauge Operation Complaint
|
SERVICE INFORMATION
|
|
Bulletin Nbr:
|
234-9001
|
|
Date:
...........
|
DECEMBER 1993
|
|
Market:
|
US
|
|
|
Fuel Gauge Operation Complaint
|
It is possible that an inaccurate or nonfunctioning fuel gauge on 1994 900 5-door models can be traced to a sender unit float wedging against the internal strengthening wall inside the tank. The fuel gauge may read empty even if the tank is filled up. See the steps outlined below to rectify this situation.
1994 900 5-door models
Warning
|
|
Always observe the following safety precautions when working on the fuel system:
|
|
•
|
NO SMOKING!
|
|
•
|
Have a fire extinguisher nearby.
|
|
•
|
Wear eye protection.
|
|
•
|
Work in a well-ventilated area. Use Vapor extraction equipment if available.
|
|
•
|
Avoid prolonged skin contact with fuel and wear suitable gloves.
|
|
|
|
|
|
|
1.
|
Remove the tank from the car and remove the fuel pump from the tank. See Service Manual 2:3 Fuel System and Air induction system, P/N 03 49 365.
|
|
2.
|
Shorten the sender unit float by 5mm on both the front and rear sides using a fine-tooth saw per Figure. File all edges round so there are no sharp corners to hang up. Although the float may now give the appearance of being porous, it is not and will not absorb gasoline.
|
|
3.
|
Refit the fuel pump assembly with newly shortened sender unit float.
|
|
4.
|
Refit the pump to the tank, taking care to align the indexing mark on the top of the pump with the mark on the tank and install the tank in the car. Be sure that all clamps are properly tightened, that the fuel lines are locked in place and that all rubber parts have been thoroughly inspected.
|
Tightening Torques:
Pump O-ring: 41 60 511 Torque to 75 Nm (55 ft.lbs.)
Hose clamp: 44 41 689 Torque to 2 Nm (17 in.lbs.)
Hose clamp: 79 70 080 Torque to 2 Nm (17 in.lbs.)
