The easiest way to test the fuel level sender is to use an assistant and remove the sending unit from the fuel tank. Turn the ignition ON , but leave the engine OFF . While your assistant watches the fuel gauge, slowly move the sending unit arm upward and have your assistant check if the fuel gauge responds accordingly. If the gauge does not move, check the circuit to the gauge, and check the gauge; if both are OK, replace the sending unit.REMOVAL & INSTALLATION
See Figures 1, 2, 3 and 4
On the Coupe, 240, 700 Series, and 940 models, the sending unit is attached to the fuel pump. See Fuel System for service information.
On the 850/C70/S70/V70 and 960/S90/V90 models, the sending unit has an access panel located in the trunk/hatch area. The procedure is as follows:
- Relieve the fuel system pressure.
- Disconnect the negative battery cable.
- Tilt the rear seat forward and remove or fold back the trunk compartment carpet over the right-hand wheelwell panel. Remove any access panels or covers as necessary.
- Disconnect the sending unit electrical wiring.
- Remove the sending units plastic retaining nut using a socket wrench and tool 999-5486 or equivalent.
- Lift the sending unit out carefully and remove the rubber seal.
- Install a new dry seal, making sure that it is seated properly. Lubricate the top and outer side of the seal with petroleum jelly.
- Install the sending unit with the wiring harness facing towards the passenger side of the vehicle.
- Remove the retaining nut from the tank and install the retaining nut on the sending unit. Tighten it to 30 ft. lbs. (40 Nm) using tool 999-5486 or equivalent.
- Connect the wiring, then install the panels, covers and carpet.
- Connect the negative battery cable.
- Run the engine and check for leaks.