Fuel Gage Issues - TSB 99-2-6

99-2-6, Publication Date: JANUARY 26, 1999

FORD:

1996-98 TAURUS

LINCOLN-MERCURY:

1996-98 SABLE

ISSUE:

The following may be fuel gauge/tank concerns:

l 1) Overfilling fuel tank/fuel gauge stays on full too long/tank holds more fuel than the rated capacity. With different fuel nozzles, filling angles and filling methods, it is possible to add more fuel than the advertised tank capacity.

l 2) Fuel gauge will not read full though the tank is full. Incorrect fuel sender installed/fuel gauge inoperative/fuel tank not filling properly.

l 3) Fuel gauge fluctuates at 1/4 tank and below while driving. Dynamic movement of fuel in tank causes gauge fluctuation during vehicle maneuvers.

ACTION:

Discuss with customer or perform the following for the listed concerns:

l 1) Inform customer to use the 3-click fill method described in the Owner's Guide. Do not continue to add fuel after the third automatic shutoff of the pump. For this issue, the fuel sender and gauge must not be replaced. Also, when the gauge is indicating at or near the "E" gradient, there could be 7.5-11 L (2-3 gallons) of fuel remaining in the tank.

l 2) Fill vehicle with fuel using 3-click method described in Owner's Guide. With vehicle on level ground, disconnect C496 and check resistance on tank side of Circuit 29 (Y/W) and Circuit 398 (BK/Y). If resistance is 155-162 ohms, tank/fuel sender is acceptable. Check forward (in the circuit) to gauge (refer to the appropriate year Taurus/Sable Service Manual, Section 13-01, Pinpoint Test C, Group 13). If sender resistance is lower, check for proper fuel sender part installed. Inspect vapor lines on top of tank for any possible restricted/crushed lines. If no problems to the lines are evident, check carbon canister, canister vent valve, and canister vent hose for restrictions.

l 3) Inform customer that gauge movement up to 1/8 tank fluctuation is normal when driving with fuel level 1/4 tank or below. Do not replace fuel sender or gauge.

NOTE:

DO NOT BEND FLOAT RODS ON FUEL SENDER IN AN ATTEMPT TO SERVICE THIS OR ANY OTHER FUEL INDICATION ISSUE. ALSO NOTE WHEN CHECKING FUEL SENDER OPERATION (ACTION SECTION ISSUE #2), EMPTY STOP SENDER RESISTANCE IS 15 OHMS AND FULL STOP RESISTANCE IS 160 OHMS UNLIKE FUEL GAUGE TEST RESISTANCE POINTS OF 22 OHMS EMPTY, 145 OHMS FULL.