1995 940 Base Fuel guage registers at or near empty.

Bkl · Post by **Bkl** » 22 Sep 2013, 20:41

Hello,
I have a problem with a fuel gauge. It has been going on for over 2 years now. Getting tired of tracking the mileage. Registers at or near empty all the time. It does change periodically when large amounts of fuel are added but it returns to the E soon there after. Also when it is Full the gauge does not show Full.

I have done the following but have not made any repair attempts.

removed instrument cluster and looked for loose connections and faulty solder pads. none were visible from what I could tell.

Removed access panel in trunk and located top of fuel pump assembly. I did not remove the pump as of yet. Just went through a learning experience in dis-assembly and locating things.

How would you advise me to proceed? should I concentrate on the gauge itself or start in the tank? And if it is in the tank, will I have to replace the whole pump or will I be able to replace only the part that is bad?
Thank You
Bkl

lindy8_man · Post by **lindy8_man** » 23 Sep 2013, 20:42

The 940 has the sending unit and the pump assembly together. It looks like you don't have to replace both. You can transfer the pump to the new assembly. Let me know if you need the steps to pull the assembly.

Bkl · Post by **Bkl** » 24 Sep 2013, 20:15

Thank you very much for responding! It would be helpful if you could give guidance in removing it. I have a pretty good idea but I would welcome the input.

Thank You!
Bruce

lindy8_man · Post by **lindy8_man** » 28 Sep 2013, 10:31

Relieve the pressure in the fuel system:
1. Pull the fuel pump relay or fuse
2. Turn on the car and wait for it to stall out.
3. Replace the relay or fuse

Remove the fuel pump:
1. disconnect the neg battery cable
2. JAck up the rear end, and support with JAck Stands.
3. Drop the tank.
4. loosen the lock ring at the top of the tank and remove the pump and sending unit.
*** Remember with the tank open, flammable fumes are present. Keep well ventilated, and away from heat and flame sources***
5. Remove the pump from the sending unit
6. install the pump on the new sending unit.
7. install the sending unit in the same direction the old one came out
8. Swap the hoses and electrical connectors.
9. Re-install the tank
10. reconnect the neg battery cable
11. Turn the key, you should hear the pump engage. Wait for it to stop, then start the car.
12. Check your fuel guage.