Fuel Gauge/Warning Light - Improper Operation

Reference:
ITB98-067

Classification:
EL98-014

Date:
February 1, 1999

1998-99 I30 FUEL GAUGE/WARNING LIGHT - IMPROPER OPERATION

APPLIED VEHICLES: 1998-99 I30 (CA32)

APPLIED VINS:

Fuel Gauge Does Not Read Full After Refueling:
Vehicles built before JNKCA21A6XT763760

Low Fuel Warning Light Goes On Prematurely:
Vehicles built before JNKCA21A*XT753472

APPLIED DATES:

Fuel Gauge Does Not Read Full After Refueling:
Vehicles built before November 17, 1998

Low Fuel Warning Light Goes On Prematurely:
Vehicles built before January 1, 1998

SERVICE INFORMATION

If an applied 1998-99 I30 has either a fuel gauge that does not read full after refueling or the low fuel warning light goes on prematurely (with over 1/4 tank of fuel), the cause may be the fuel level sender unit.

A new fuel level sender unit is now available to correct both of the above conditions, if they should occur.

Use the procedures below to confirm that either of the above conditions exist. Once confirmed, remove and replace the fuel level sender unit using the following procedure.

SERVICE PROCEDURE

1. Fuel gauge does not read full after refueling the vehicle:

A. Verify the condition exists.

B. If confirmed, remove the rear seat bottom cushion (refer to rear seat removal, located in the BT section under SEAT/Rear Seat on page BT-30 of the 1998 and 1999 I30 Service Manuals).

C. Protect seat belts from damage or dirt.

D. Remove the sheet metal cover plate to gain access to the fuel tank.

Warning: Prior to removing any fuel line parts, release fuel pressure from the fuel line to eliminate the chance of injury. Use the appropriate procedure located in the EC section under BASIC SERVICE PROCEDURE/Fuel Pressure Release, page EC-29 of the 1998 I30 Service Manual or page EC-37 of the 1999 I30 Service Manual.

E. Disconnect rubber hoses from the fittings on the fuel level sender unit (refer to page FE-3 of the 1998 or 1999 I30 Service Manuals).

F. Remove the fuel level sender unit retaining ring from the fuel tank.

G. Disconnect the fuel pump assembly from the fuel level sender unit.

H. Remove the fuel level sender unit from the fuel tank and conduct the following bench test:

Figure 1:

1) Turn the fuel level sender unit upside down so that the float arm contacts the "Full" stop (see Figure 1).

2) Use a digital voltage-ohm meter (DVOM) to measure resistance across terminals "E" and "G" (see Figure 1). Use the appropriate procedure located in the EL section under METERS AND GAUGES/Electrical Components Inspection/Fuel Tank Gauge Unit Check, page EL-81 of the 1998 I30 Service Manual or page EL-91 of the 1999 I30 Service Manual.

I. If the measured resistance value is within specification (under 6 ohms),use the "wiggle" test to check the wire harness for intermittent open circuits.

J. If the measured resistance value is over 6 ohms or is unsteady, replace the fuel level sender unit with the part listed in the PARTS INFORMATION section of this bulletin.

1) Install the replacement fuel level sender unit using the appropriate procedure located in the FE section under FUEL SYSTEM, page FE-3 of the 1998 or 1999 I30 Service Manuals.

NOTE: When replacing the fuel level sender unit, always replace the O-ring and hose clamp (see the Parts Information section of this bulletin).

Be sure the hose clamp on the output side of the fuel pump is securely fastened to the fuel level sender unit.

2) Check for fuel leaks before re-installing the sheet metal cover plate.

3) Re-install the rear seat bottom cushion.

NOTE: Make sure the seat belt buckles are above the cushion when re-installing.

2. The low fuel warning light goes on prematurely (with over 1/4 tank of fuel):

A. Verify the condition exists.

B. If the condition exists, replace the fuel level sender unit with the part listed in the PARTS INFORMATION section of this bulletin. Use the installation procedure below.

1) Install the replacement fuel level sender unit using the appropriate procedure located in the FE section under FUEL SYSTEM, page FE-3 of the 1998 or 1999 I30 Service Manuals).

NOTE: When replacing the fuel level sender unit, always replace the O-ring and hose clamp (see the Parts Information section of this bulletin).

Be sure the hose clamp on the output side of the fuel pump is securely fastened to the fuel level sender unit.

2) Check for fuel leaks before re-installing the sheet metal cover plate.

3) Re-install the rear seat bottom cushion.

NOTE: Make sure the seat belt buckles are above the cushion when re-installing.





PARTS INFORMATION

CLAIMS INFORMATION





Submit a Primary Failed Part (PP) line using the claims coding as shown.