940 Highlander 1993 Fuel Guage Fault

Sep 9th, 2004, 16:50

Has anybody with a 940 had a fuel guage that works after a few miles and spends most of its time showing empty. It bursts into life when going around sharp corners or when hitting a bump and then appears to work until the engine is stopped. Sometimes it will work when I start the engine but mostly it will not! What are the possible problems and how do you fix it?

Sep 9th, 2004, 17:34

sounds like a dodgy connection exasperated by heat. i couldnt tell you where thou

Sep 9th, 2004, 19:48

http://pic7.picturetrail.com/VOL188/...8/23744414.jpg

With the tank unit disconnected (there is a 3 wire connector inside the car next to the L/H rear wheel arch) the gauge should read full.

If it doesn`t the fault is at the guage end, probably a bad connection on either the feed or earth to the instrument.

Clean and check the multi-plugs that go in the back of the instrument cluster.

If that doesn`t sort it, remove the screws one at a time that hold the guage into the cluster and gently clean the underside of the screw heads and the flexible printed circuit were they make contact.

An invisible layer of oxide here has been known to cause problems.

The guage can sometimes be got going by the less scientific method of giving the dash top a whack with your hand !!

The sender unit, by the way, should give from 0 ohms empty to 250 ohms full.

Colin.

1990 740SE B200E/M47, remote C/Locking.

Sep 11th, 2004, 08:29

Hi Colin

Yesterday I was playing with the connector you mentioned. The tank side reading was 21-OHMS which corresponds to a three quarters full tank. I scrapped the tank side sender male connector contacts clean and on the instrument side connector I bent the female contacts so as to give a tighter grip. So there is no movement I tied the connector and wiring firmly to the bodywork using a cable tie. The fuel gauge now appears to work. The tank sender and fuel pump assembly had been out of the car at some point in the past and I suspect it is another case of let a Volvo Dealer or third part Garage touch the car at your own peril! They had made a right mess of putting it back and had even broken the plastic bit that holds the the whole unit in place.

Regards

SR

Sep 9th, 2004, 16:50	#1
Stowpirate Guest Location:	940 Highlander 1993 Fuel Guage Fault Has anybody with a 940 had a fuel guage that works after a few miles and spends most of its time showing empty. It bursts into life when going around sharp corners or when hitting a bump and then appears to work until the engine is stopped. Sometimes it will work when I start the engine but mostly it will not! What are the possible problems and how do you fix it?

Sep 9th, 2004, 17:34	#2
5lab Guest Location:	RE: 940 Highlander 1993 Fuel Guage Fault sounds like a dodgy connection exasperated by heat. i couldnt tell you where thou

Sep 9th, 2004, 19:48	#3
Colin Shepherd Guest Location:	RE: 940 Highlander 1993 Fuel Guage Fault http://pic7.picturetrail.com/VOL188/...8/23744414.jpg With the tank unit disconnected (there is a 3 wire connector inside the car next to the L/H rear wheel arch) the gauge should read full. If it doesn`t the fault is at the guage end, probably a bad connection on either the feed or earth to the instrument. Clean and check the multi-plugs that go in the back of the instrument cluster. If that doesn`t sort it, remove the screws one at a time that hold the guage into the cluster and gently clean the underside of the screw heads and the flexible printed circuit were they make contact. An invisible layer of oxide here has been known to cause problems. The guage can sometimes be got going by the less scientific method of giving the dash top a whack with your hand !! The sender unit, by the way, should give from 0 ohms empty to 250 ohms full. Colin. 1990 740SE B200E/M47, remote C/Locking.

Sep 11th, 2004, 08:29	#4
Stowpirate Guest Location:	RE: 940 Highlander 1993 Fuel Guage Fault Hi Colin Yesterday I was playing with the connector you mentioned. The tank side reading was 21-OHMS which corresponds to a three quarters full tank. I scrapped the tank side sender male connector contacts clean and on the instrument side connector I bent the female contacts so as to give a tighter grip. So there is no movement I tied the connector and wiring firmly to the bodywork using a cable tie. The fuel gauge now appears to work. The tank sender and fuel pump assembly had been out of the car at some point in the past and I suspect it is another case of let a Volvo Dealer or third part Garage touch the car at your own peril! They had made a right mess of putting it back and had even broken the plastic bit that holds the the whole unit in place. Regards SR

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