940 fuel gauge sender - replacement?

[Mattty]

Hi all,

My fuel gauge has been playing up for a while in my 97 940 estate. If its low(ish) and I park up, a few hours later it will show as empty until I give it a hard sloshing about or go over a bump and it will rise back up slightly on the gauge. I brimmed the tank earlier and the gauge was reading below full, I'd say about 90% full, then by the time I had driven home it was showing 3/4 full so something is definitely up.

My initial thoughts point straight to the fuel gauge sender, though couldn't find a replacement one online. Does anyone know if there are any aftermarket senders or will I have to go to Volvo? and any tips for replacing it? Im assuming its like most cars with the sender built onto the in-tank pump.

Cheers

[Laird Scooby]

Originally Posted by Mattty

and any tips for replacing it?
Cheers

Yeah - don't bother! What you've described there is a typical fuel gauge. Some people are lucky and their gauges still work as Volvo intended, others, like yourself have one that works like a 1970s coal miner - when it wants to and then only half a job!

You'll need a new seal from Volvo for the in-tank pump/sender unit, they're about £11 but i can't remember the part number just now.

Is it a saloon or estate? If estate, you need to remove the fold down panels once the rear seats have been tipped forward to reveal the access plate. Remove that and become a gynaecologist to remove the in-tank pump/sender unit.
Saloon is similar but you're in the boot to remove the access plate.

[aardvarkash10]

adding to Dave's typically extensive response:

The fuel gauge sender float slides (supposedly) inside an outer tube. Hanging off the entire mess is the tank fuel pump. It is prone to stiction, especially at the bottom of its travel.

Having just recently done it, I'm not convinced pulling it all out and replacing the sender is worth the heartbreak and skinned knuckles. Its one of those jobs best attempted after three years training as a gymnastic gynecologist. A full working knowledge of anglo-saxon vernacular is useful as well.

[gpl1968]

On my 940 the fuel gauge stopped working a some years ago. With help from the FAQ I diagnosed the sender unit to be the problem.



The pic shows the contacts that are attached to the float and slide up and down the resistor wires of the level sender. The left hand one is new and the rectangular plates at the end of the two arms slide along the resistor wires and over time wear out.
On mine the centre of each plate wore away until the jagged edges stuck on the wires. I managed to replace the contacts by silver-soldering nickel silver rectangles onto the arms of the contactor and the repair has been mostly successful. The gauge tells me when the tank is full and empty. In between it's a bit vague.

[Stephen Edwin]

Originally Posted by Laird Scooby

Yeah - don't bother! What you've described there is a typical fuel gauge. Some people are lucky and their gauges still work as Volvo intended, others, like yourself have one that works like a 1970s coal miner - when it wants to and then only half a job!

You'll need a new seal from Volvo for the in-tank pump/sender unit, they're about £11 but i can't remember the part number just now.

Is it a saloon or estate? If estate, you need to remove the fold down panels once the rear seats have been tipped forward to reveal the access plate. Remove that and become a gynaecologist to remove the in-tank pump/sender unit.
Saloon is similar but you're in the boot to remove the access plate.

Originally Posted by aardvarkash10

adding to Dave's typically extensive response:

The fuel gauge sender float slides (supposedly) inside an outer tube. Hanging off the entire mess is the tank fuel pump. It is prone to stiction, especially at the bottom of its travel.

Having just recently done it, I'm not convinced pulling it all out and replacing the sender is worth the heartbreak and skinned knuckles. Its one of those jobs best attempted after three years training as a gymnastic gynecologist. A full working knowledge of anglo-saxon vernacular is useful as well.

Originally Posted by gpl1968

On my 940 the fuel gauge stopped working a some years ago. With help from the FAQ I diagnosed the sender unit to be the problem.



The pic shows the contacts that are attached to the float and slide up and down the resistor wires of the level sender. The left hand one is new and the rectangular plates at the end of the two arms slide along the resistor wires and over time wear out.
On mine the centre of each plate wore away until the jagged edges stuck on the wires. I managed to replace the contacts by silver-soldering nickel silver rectangles onto the arms of the contactor and the repair has been mostly successful. The gauge tells me when the tank is full and empty. In between it's a bit vague.

I am wondering how much of this applies to the 240.

And.

Is there a strong way around this issue?

[360beast]

I watched a YouTube video on how to get it out of a 740 as practice for my 940, in the video he managed to get it out in less than a minute once he had access to it... I struggled and swore lots and eventually somehow it came out.