Instruments - Fuel Gauge Won't Read 'FULL'
No: 19/01/99/NASRef:
Issue: 1
Date: 01/22/99
Fuel Gauge Indication with Full Tank
AFFECTED VEHICLE RANGE:
RANGE ROVER (LP) up to XA410504
SITUATION:
The fuel gauge on vehicles before the above VIN may not indicate "Full" after the tank has been filled. This is caused by a build-up of contaminants on the fuel gauge sender unit. The contamination increases the sender unit resistance in the full position, which causes the gauge to incorrectly indicate a lower fuel level.
In addition to the above symptom, the sending unit on vehicles equipped with advanced evaporative loss systems (98 model year and onwards) was incorrectly calibrated. The calibration used causes the gauge to indicate "full" immediately after fill-up, but then move away from full as soon as the vehicle is driven.
RESOLUTION:
A new fuel sender is available which uses a contamination resistant alloy for both the sweeper and contacts. For advanced evaporative loss vehicles, the resistance profile of the sender has also been re-calibrated to prevent the gauge from prematurely indicating a drop in fuel level.
For a customer complaint of low fuel gauge indication when the tank is full, or when the fuel gauge drops rapidly below the full line when the vehicle is driven following refueling, replace the sender unit as outlined below.
PARTS INFORMATION
WARRANTY CLAIMS
Normal warranty policy and procedures apply.
REPAIR PROCEDURE:
REMOVAL AND INSPECTION OF SENDING UNITS
1. Refer to Workshop Manual Section 19.55 and remove tank pump/sending unit assembly.
2. Disconnect sender electrical leads from the top of the tank unit.
NOTE:
Vehicles before VIN TA323599 were originally equipped with VDO fuel gauge senders which are not serviceable. However, the tank unit may have been replaced in service with the later design that does have a serviceable sender.
3. Inspect sending unit to determine repair requirements:
^ If the sender is marked "VDO", replace the entire tank unit with a "38A/G" configuration tank unit ESR3931.
^ If the sender is marked "38A", do not replace the entire tank unit. Perform the repair installation of the latest configuration sender marked with a "G" suffix.
REPAIR OF 1995-1997 VEHICLES-NON VDO
1. Push fuel pump hose aside slightly to gain access to single "Pozidriv" screw securing sender assembly to pump body.
2. Remove "Pozidriv" screw.
3. Remove sender from pump housing.
4. Assemble sending unit (WGI1000002) to pump housing and tighten "Pozidriv" screw.
REPAIR OF 1998 AND 1999 GEMS-EQUIPPED VEHICLES
1. Remove rubber base from tank unit.
2. Remove sender bracket from tank unit assembly.
3. Disconnect sender unit cables from flange.
4. Install sender/bracket assembly onto tank unit.
5. Install rubber base onto tank unit.
6. Connect sender unit cables from flange.
INSTALLATION OF CORRECTED TANK UNIT
1. Connect sender electrical leads to the top of the tank unit.
2. Refer to the Workshop Manual and install new or repaired tank unit assembly.