Fuel Gage TSB 99-15-1

99-15-1, Publication Date: JULY 9, 1999

FORD:

1999 TAURUS

MERCURY:

1999 SABLE

ISSUE:

The following may be fuel gauge/tank concerns:

1. Slow fuel fill at or ABOVE 3/4 of a tank/fuel fill nozzle clicks off. The fueling station's fill nozzle is incompatible with the vehicles On-board Refueling Vapor Recovery System (ORVR system) or has a higher than normal fill rate.

2. Slow fuel fill BELOW 3/4 of a tank/continuous fill nozzle clicks off. Blocked/crushed evaporative emission lines or blockage in the fuel filler neck or an ORVR incompatible fuel fill nozzle.

3. The low fuel light illuminates with 11-22 L (3-6 gallons) of fuel remaining and/or the customer can only add 38-45 L (10-12 gallons) of fuel. The low fuel light will illuminate on level surfaces with approximately 11 L (3 gallons) of fuel and 15-22 L (4-6 gallons) when on hills or during/after extended turns.

4. Fuel gauge does not update after fuel fill. The fuel gauge will not update for several minutes after filling if the vehicle is running or the ignition switch is left in the Run position. This is due to a normal anti-fluctuation slosh module time delay strategy.

5. The fuel gauge needle drops off full shortly after fill-up. The fuel level sender and gauge are calibrated to accurately represent a COMPLETELY FULL indication. Driving approximately 48 km (30 miles) will start to move the fuel gauge needle off of full.

6. The fuel gauge fluctuates at or below 1/4 tank. The fuel gauge fluctuation is due to normal operation of the slosh module time delay strategy. This prevents excessive fuel gauge needle movement.

ACTION:

Verify customer concern(s) and discuss or perform the following for the 6 listed concerns.

SERVICE TIPS

1. Use the following 3-click fill method: Fill fuel at the fastest fill rate until first click. Allow approximately 5 seconds and continue to fill at the slowest rate until second click. Then pull fuel nozzle back approximately 25mm (1") and fill at the slowest rate until third click. This fill method should provide a complete fill. Recommend that customer try a different fill station and use this method.

2. Inspect the three (3) evaporative emission vent hoses that are attached to the carbon canister for blockage/kinks. Check filler pipe for blockage. Inspect evaporative emission hoses between the fuel tank and floor pan for crush/kinks/blockage (this inspection can be performed by lowering the fuel tank).

3. Normal system operation. Review the customer's drive pattern that triggered the low fuel light and compare with the normal operation.

4. The ignition must be in the Off position during fuel fill (as stated in the Owner's Manual). This allows instant calibration between the fuel level and fuel guage.

5. Normal system operation.