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by Erics40
06 Mar 2009, 06:52
Forum: Volvo S40 & V40 2000-2004
Topic: Service Manuals & Fuel Capacity
Replies: 18
Views: 8385

Re: Service Manuals & Fuel Capacity

Just a brief update on the fuel tank issue for those still in doubt. I performed the above sender modification some months ago and have used countless tanks since. When the light comes on, I have about two gallons remaining in the tank. When the "Range to Zero" indicator reads "0"...
by Erics40
04 Nov 2008, 08:31
Forum: Volvo S40 & V40 2000-2004
Topic: Service Manuals & Fuel Capacity
Replies: 18
Views: 8385

Re: Service Manuals & Fuel Capacity

Here's the final result. I have adjusted the resistance to read 104 ohms when the pump/sender unit and the float are both on the table. This pops the fuel light on at 14.5 gallons, leaving the reserve amount to 1.5 gallons. The float arm has to be bent 'shorter' (closer to the sender body) so the fl...
by Erics40
14 Oct 2008, 20:33
Forum: Volvo S40 & V40 2000-2004
Topic: Service Manuals & Fuel Capacity
Replies: 18
Views: 8385

I had yesterday off and just couldn't leave well enough alone. I pulled the fuel pump and sender assembly and bent the arm. At the mount end, I bent the wire straighter making the float rise and extend. It probably moved out a half inch and up a half inch. Then I bent the lower kink to make the floa...
by Erics40
12 Oct 2008, 19:59
Forum: Volvo S40 & V40 2000-2004
Topic: Service Manuals & Fuel Capacity
Replies: 18
Views: 8385

Hi Bill, Thanks for the continuity. More on the sender and fuel level issue- The pictures of the sender show a float and a wire that may be able to be bent to accommodate the sender electronics. It seems the float is actually two thirds of the travel, so I may pull it to see if it will go that far. ...
by Erics40
09 Oct 2008, 07:29
Forum: Volvo S40 & V40 2000-2004
Topic: Service Manuals & Fuel Capacity
Replies: 18
Views: 8385

Hi all, Well, the great gas tank experiment is over. I ran the car to empty and got 474 miles, validating the owners maunal. I have been getting about 30 mpg so this mileage proves the 16 gallons in the tank and a smidge under 30 mpg. Yes I did have a 1 gallon can in the trunk. So now the head scrat...
by Erics40
08 Oct 2008, 07:49
Forum: Volvo S40 & V40 2000-2004
Topic: Service Manuals & Fuel Capacity
Replies: 18
Views: 8385

I too have discovered the short tank. I am now running the tank dry to see how far I can go. I will post results when I have info.