i done my replacement last year and yes this should solved your problem for good...

another thing to caution when re install the fuel pump assembly back in tank make sure the cable that connected to item#3 are away from the floater..otherwise it will effected the measurement as well..

 

Re: Fuel Level Sender (Skot53)

Wasn't or isn't there a recent TNN on this very issue for 2004's??

 

Re: Fuel Level Sender (Short Circuit)

You may be thinking of the fuel pump TNN... I got a letter in the mail for that one, but my car has already been fixed.

 

Re: Fuel Level Sender (Skot53)

Quote, originally posted by Skot53 »

Hi, I have a problem with my fuel level gauge. When it gets to 1/2 tank to around 1/4 tank, it intermittently reads empty. So- I took apart the backseat and got into the fuel tank (filthy down there!), found the problem...

So what is the problem? Does the photo show something obviously wrong/broken?

 

Re: Fuel Level Sender (jclough)

The electrical contacts are burned on the level sensor so bad that it isn't making a good connection anymore.

update not worth bumping:

Items Ordered:
Item: Fuel gauge sending unit, s60, left, w/r model 2004 - 2007
Price: $70.31
Tax: $0.00
Qty: 1
Total: $70.31

Another update not worth bumping:
The problem still exists after the fuel level sender installation, but it doesn't seem as severe. I think it may be just the nature of the car. It seems to fluctuate due to the style of driving. Example: Driving calmly on the freeway at 55MPH, the needle stays normal, proportionate to the amount of fuel actually in the car.

Drive in heavy traffic, or drive aggressively, the needle reads conservatively, indicating less fuel than the tank actually has.

 

Hey Scot53, quick question. It seems in the diagram that the sender unit is separate from the fuel pump, is that the case? I am asking because I just took my 04 R in for the fuel pump recall and they messed up the wiring for the sender unit. They say it was worn out and fell apart on its own when they were taking it out, and it is not their responsibility, since they HAD to touch that part to replace the fuel pump. Am I just being paranoid or are they giving me a bunch of bull? Because if they are separate, they shouldn't have been touching my sender unit at all. My gauge hasn't worked after they "fixed" my fuel pump... Thanks!

 

I have this issue too, and got a CEM code "CEM-4A38 Fuel Level Sensor Short Circuit to Ground". If replacing the fuel level sensor doesn't fix it, what is the problem?

Mine will just randomly drop to E, and many times restarting the car will bring it back up.

 

I took my 2006 V70R in for service on the fuel gauge problem. Mine would just drop to Zero and no miles to empty would be displayed. If I pulled over and turned the car off it would function again. The dealer said I need a fuel pump unit for ........$800.00 to fix it. They also said there was a code for "Shorted sending unit on fuel pump side "

What parts do I need ? If a fuel pump IS needed is there a upgrade pump recommendation ? BTW the car ran fine all the way up to 156 and had great passing power this last trip to Vegas.

Also had a problem with the rear cargo light not working. They said it was a shorted out LED ( did a full EST LED kit ). What is the proper part number for the rear cargo LED ?

Ron

 

If anyone has a solution to this let me know. I am currently working on several cars with similar issues. I have a 99 S80 T6 and a 2005 S60 that both of their fuel gauges are not working correctly. The S60 believes it has a full tank all the time and the S80 never registers a full tank.

The S60 I am dropping the tank now (It's a California emissions car, damn their green-ness), and the S80 I have been all over. I've replaced the fuel level sensor even, and still no good. It acts as if something is restricting the float when it's in the car, but if the sending unit is out of the tank everything works perfectly.

 

Check to make sure the float isn't binding on anything in the tank.

 

I have checked that, but it's impossible to see exactly what is going on inside the tank when the sending unit is in place. I am pulling the unit again to make sure, but I was wondering if anyone else has encountered similar issues.

Update on the S60 - the appears to be an actual fault in the instrument cluster. We are making inquiries on whether or not the instrument clusters can be repaired.

 

There are 2 fuel level sensors. One connected to the pump assy and one on the other side of tank. the level sensor by fuel pump can be replaced seperately and is usually the source of faulty readings below half a tank.

 

Yes, I know there are two. Currently on the low end they read correctly, but it wont go to the high end. Oddly enough, originally the levels were reading high and we ran out of gas with a quarter tank showing in the cluster. I changed out both sensors and then with the tank empty the cluster still ready high. With Modis both sides read roughly a gallon-and-a-half more more than was physically in the tank.

I physically modified both sensors so that the arm on the float would drop lower to read the correct amount in the tank. All was well and good until I filled the tank. Then the level would not go above 3/4 tank. Today I swapped the passenger side float and immediately Modis started registering more fuel than was in the tank again (one and a half) for that side. Now here's my big question at the moment is, why? The S80 has larger gas tank 21.1 gallons vs. for example the S60's 18.5 gallons. But the number for the level sensor is a universal fit to all of the models Volvo produced from 99 up to 05 or so. Perhaps if the gas tank is larger because of the height of the tank and perhaps that's where the problem is? The level sensors I have swapped out I don't know what model they came out of, but that's the only thing I have except for a fault in the instrument cluster.

I just got Vida online last night, so perhaps I would try reprogramming the cluster...

 

No the orange empty warning does not come on. It happens at all level . I was just wondering if I could just replace the sensor instead of the whole fuel pump. But if it needs to be replace I wanted to go with the best pump I could.

 

Using VIDA to look at CEM-Fuel Level Left and Right, I see a significant difference between L and R level sensors. Seems my Right sensor matches what I see at the gauge but my Left sensor is always showing way less fuel.
Anyone else check L and R level with VIDA?

L showing 6.5L, Right showing 22.5L:

L showing 9.5L, Right show 16L. Looking at the graph there is a period (while I was stopped) that Left showed 0L. This often happens while stopped (L shows 0).

Does this indicate I have a failed Left Fuel Level Sensor?

LTA

 

I had this exact problem with the gauge dropping to zero, especially after the car heated up or when the weather was warm. I replaced my driver's side fuel level sender, part number 8683142 ($72 from Tasca), and it solved the issue.

 

Nevermind. The behavior just took a couple days off, the sender did not fix it. Anyone solve this yet?

 

You changed the left/driver side sender. Did you get DTC's for the right/passendger side sdnder?

LTA

 

I found some info and threads:

This one sounds promising, but it is not for my fault code:
http://www.v70xc.com/resources/how-to/pdf/instruments-fuel-guage-reads-zero-with-fuel-in-tank.pdf

Threads:
http://forums.swedespeed.com/showthread.php?150334-Fuel-Gauge-Entertainment&p=1621809
http://forums.swedespeed.com/showthread.php?162079-Gas-guage-going-dead&

I wish I would have looked up the code before replacing the sensor.

372: CEM-4A38 Fuel level sensor. Short-circuit to ground

Diagnostic trouble code (DTC) information CEM-4A38

Condition
The central electronic module (CEM) continuously checks the signal from the sensor on the pump side which indicates the level in one of the fuel tanks.
The diagnostic trouble code (DTC) is stored if the central electronic module (CEM) registers a short-circuit to ground in the sensor.
The diagnostic trouble code (DTC) can be diagnosed when the ignition is switched on.

Substitute value
The fuel level is set to zero.
Possible source
Short-circuit to ground in the sensor on the pump side.

Fault symptom
The trip computer displays an empty fuel tank too early.
The fuel gauge indicates zero even though there is fuel in the tank.

It looks like the pump side sensor is available seperatly, for 2005+, the P/N is:
8621813 or
30742664

Looks like I will have to call Tasca again. Sigh.

 

Recently, Bigfieroman described a problem I have had for the last year. He wrote (in part):

(BEGIN QUOTE): CEM-4A38 Fuel level sensor. Short-circuit to ground

Diagnostic trouble code (DTC) information CEM-4A38

* * *

It looks like the pump side sensor is available seperatly, for 2005+, the P/N is:
8621813 or
30742664

Looks like I will have to call Tasca again. Sigh.[/QUOTE] (END QUOTED SECTION)

NEW CONTENT STARTS:

I believe I have the same problem with my 2005 V70R for about a year. This may merit a separate thread, but let's try here first.

Error codes include CEM 4A38 (Fuel Level Sensor. Short-circuit to ground), ECM 440C (Fuel tank sensor. Signal too high), and ECM 400C (Fuel Tank System Leakage).

Description: The problem most frequently occurs after filling the tank; fuel gauge drops to 0, distance to empty reads ---, check engine light comes on. System eventually resets itself and even clears the check engine light. The issue is intermittent. Possibly related: (1) when the fuel gauge works, the needle appears to be accurate; behavior does not match that of the "incorrectly displayed partial tank fuel levels" others have described; and (2) distance to empty displayed by the on-board computer is quite optimistic when the tank is newly filled, as though it held more than it actually does. The predictions are quite accurate in the lower range of the fuel tank.

Other codes, possibly related, are CEM 1F00 (ECM Software. Faulty Signal) and ECM 5110 Malfunction Indicator Lamp (MIL) CEM Faulty Signal). However, the car has a Stage 2 MTE software upgrade and I do not know whether that is throwing the OEM system unexpected values that trigger these indicators.

I am very much interested in experience of others: is this a software error or a physical, intermittently occuring short? Has anyone dealt with this problem successfully? Thanks in advance for any info/helpful suggestions.

 

It seems like replacing the pump side sensor, which was a MASSIVE PITA, has solved the problem. Of course, now that I have said that, the behavior will show back up. We'll see.

 

Did it ever solve the problem? Do you remember?

 

Resurrecting this thread. My wife's 07 S60R has a similar issue. The needle drops below empty. There is no low fuel light. The display shows ----- to empty.

It sounds like this might be an issue with the sending unit next to the fuel pump. Does anyone know which wires to attach to an ohm meter to test the sending unit?

Any input would be appreciated!

 

Topic resurrection.

After replacing the rubber gasket both sides (pump and sender) the level gauge started acting up. It intermittently reads empty, DIM shows "---- to empty"and then returns. The orange low fuel light does NOT come on when the needle drops to zero.
Before replacing the gaskets, it was working without faults. The the pump is around 1 year old: http://www.skandix.de/en/spare-parts/engine/fuel-mixture-formation/fuel-supply-system/pumps/fuel-feed-unit-electric/1053793/

 

It could be coincidence or maybe you jostled a connector. Connect to VIDA and monitor fuel level signals. That should tell you more about what's going on.

 

Fuel level sending unit

Having the same problem with my 06 S80. I ordered the unit and o-ring and hope that will fix the issue. BTW, the parts cost $42.73 shipping included.

 

I had issues as well, with a BRAND NEW Bosch fuel pump from FCP.

For clarity, there are two level sensors on the P2's. One on the pump, and one opposite of the pump (and you don't have to worry much about the cable snagging that because it clips onto it)

The issue for me was the new fuel pump sensor pins, just weren't making great contact. I ended up bending the pins (they are very delicate) and it fixed it for a while but came back. Swapped the pump with FCP and it fixed it.