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Fuel tank sensor

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Old May 23rd, 2020, 13:57   #1
P156KWJ
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Default Fuel tank sensor

2002 S40 1.9D

Had an intermittent fault that's been going on for some time but is now pretty much permanent. No doubt has been discussed somewhere before!

Filled up yesterday to the top, fuel gauge won't read maximum, but sometimes a day or two later it'll be up at max, so I know it isn't an early triggering of forecourt fuel pump turn off.

Is there a known fault with a step by step repair method or is it easier to ignore?
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Old May 24th, 2020, 11:58   #2
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Hi there, this happened to me with my petrol 1.8 2004 S40, it appears to be a common problem, eventually the gauge will stop working altogether and the fuel warning light will stay on.
My best advise is to fit a new unit (do not go for a second hand one) shop about to get the best price, I managed to get a brand new Bosch unit for £81 after hours of surfing or if you do not intend keeping the car very long just keep doing what you are doing and fill the tank and zero the tripmeter (this is what I did for several months). funnily enough I just had my new Bosch unit fitted a couple of days ago by a local mechanic and all working fine now.
One last bit of advise, if you decide to fit a new unit get yourself a new rubber gasket (approx £13) as the old one will be hard and brittle
Hope this helps
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Old May 24th, 2020, 14:59   #3
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Quote:
Originally Posted by coljol View Post
Hi there, this happened to me with my petrol 1.8 2004 S40, it appears to be a common problem, eventually the gauge will stop working altogether and the fuel warning light will stay on.
My best advise is to fit a new unit (do not go for a second hand one) shop about to get the best price, I managed to get a brand new Bosch unit for £81 after hours of surfing or if you do not intend keeping the car very long just keep doing what you are doing and fill the tank and zero the tripmeter (this is what I did for several months). funnily enough I just had my new Bosch unit fitted a couple of days ago by a local mechanic and all working fine now.
One last bit of advise, if you decide to fit a new unit get yourself a new rubber gasket (approx £13) as the old one will be hard and brittle
Hope this helps
Cheers for the help!

Which unit are you on about or do you mean the fuel gauge assembly itself?
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Old May 24th, 2020, 16:15   #4
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Scratch that, see what you mean now, few and far between on Ebay but I'll keep an eye out! Just lifted the carpet up to have a look and seems a relatively easy fix (he says, optimistically)
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Old May 27th, 2020, 10:00   #5
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If you go to
http://www.volvohowto.com/how-to-rep...o-s40-and-v40/
detailed instructions on removal
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Old May 27th, 2020, 10:12   #6
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Just noticed your car is diesel so according to the info on volvohowto.com

"The 1.9D, 1.9TD and 1.8 GDI S40 and V40 don’t have the pump in the sender unit and instead use the high pressure pumps in the engine compartment."

So make sure you get the correct unit for your car
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Old May 27th, 2020, 18:42   #7
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Quote:
Originally Posted by coljol View Post
If you go to
http://www.volvohowto.com/how-to-rep...o-s40-and-v40/
detailed instructions on removal
Extremely useful thank you.

Proving practically impossible to source new so it seems. With the exception of Volvo directly, who want £230 ish as it is a bespoke part. And they no longer make the rubber gasket. I'm tempted to have a look and see if the current one is salvageable and clean the contacts up to see if it will read properly.
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Old May 28th, 2020, 09:40   #8
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Hi again
After some research it appears that some diesel fuel pump/sender units have 3 pipe connections others only have two, best way to make sure you get the correct unit is to look at the top of your unit where there should be the part number of the unit fitted to your car, you can then use this number to surf the net for a replacement
Personally I would not go to all the bother of removing your existing unit to try cleaning the potentiometer as the track will be worn and cleaning will not sort that
Good luck
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