Signal Too High
WARNING: Test drive cars with AWD at a speed above 20 km/h (12 mph), or lift up the front and rear suspension and remove all wheels.
NOTE: The Volvo All-wheel drive (AWD) has a different fuel tank with two fuel level sensors connected in series.
BB1 Checking Fuel Level Sensor Resistance:
- Ignition off.
- Disconnect fuel level sensor connector according to DDL1 - DDL2 for 4-door cars and DDL4 - DDL5 for 5-door cars. Service and Repair
- Connect an ohmmeter between terminals 1 and 2 in the fuel level sensor connector. The ohmmeter should read 10-325 Ohms, depending on fuel level. Specifications
If reading is OK: BB3
If reading is incorrect: BB2
BB2 Replacing Component:
Try a new fuel level sensor. Then continue with BB18.
BB3 Checking Ground Lead Resistance:
- Ignition off.
- Fuel level sensor disconnected.
- Connect an ohmmeter between fuel level sensor connector terminal 1 (cable harness side) and ground. The ohmmeter should read approximately 0 Ohms.
If reading is OK: BB9
If reading is incorrect: BB4
BB4 Checking Ground from Combined Instrument Panel:
- Ignition off.
- Fuel level sensor disconnected.
- Connect the breakout box and check ground terminals. Connecting the Breakout Box
- Connect combined instrument panel.
- Connect an ohmmeter between # 4 (# A4) and # 15 (# A15) on the breakout box. The ohmmeter should read approximately 0 Ohms.
If reading is OK: BB8
If reading is incorrect: BB5
BB5 Data Read-Out:
Read off all data from the combined instrument panel control module and note values. Then continue with BB6.
NOTE: For information see "Reading Off and Programming Combined Instrument Panel". Reading Off and Programming Combined Instrument Panel
BB6 Replacing Component:
Try a new connection plate according to DDJ. Replacing Connection Plate. Service and Repair Then continue with BB7.
BB7 Programming Combined Instrument Panel:
Program the control module with the values previously read off the combined instrument panel control module. Then continue with BB18.
NOTE: For information see "Reading Off and Programming Combined Instrument Panel".
BB8 Checking for an Open-Circuit:
Check cable between combined instrument panel # A4 and fuel level sensor for an open-circuit according to ZA2. Permanent Faults Then continue with BB18.
BB9 Checking Signal to Fuel Level Sensor:
- Ignition on.
- Fuel level sensor disconnected.
- Connect a voltmeter between connector terminals 1 and 2 (cable harness side). The voltmeter should read 6-8 V.
If reading is OK: BB10
If value is higher: BB12
If value is lower: BB13
BB10 Checking Fuel Level Sensor (Removed):
- Ignition off.
- Remove fuel level sensor.
- Hold the fuel level sensor the right way up.
- Connect an ohmmeter between terminals 1 and 2 in the fuel level sensor connector. The ohmmeter should read approximately 325 Ohms.
If reading is OK: BB19
If reading is incorrect: BB11
BB11 Replacing Component:
Try a new fuel level sensor according to DDL8. Service and Repair For AWD see SM 2-23-823. Then continue with BB18.
BB12 Checking for a Short-Circuit to Supply Voltage:
Check cable between combined instrument panel # A5 and fuel level sensor for a short-circuit to supply voltage according to ZA4. Permanent Faults Then continue with BB18.
BB13 Checking Signal from Combined Instrument Panel:
- Ignition off.
- Fuel level sensor disconnected.
- Connect the breakout box and check ground terminals. Connecting the Breakout Box
- Connect combined instrument panel.
- Ignition on.
- Connect a voltmeter between # 4 (# A4) and # 5 (# A5) on the breakout box. The voltmeter should read 6-8 V.
If reading is OK: BB14
If reading is incorrect: BB15
BB14 Checking for an Open-Circuit:
Check cable between combined instrument panel # A5 and fuel level sensor for an open-circuit according to ZA2.Permanent Faults Then continue with BB18.
BB15 Data Read-Out:
Read off all data from the combined instrument panel control module and note values. Then continue with BB16.
NOTE: For information see "Reading off and programming combined instrument panel". Reading Off and Programming Combined Instrument Panel
BB16 Replacing Component:
Try a new connection plate according to DDJ. "Replacing Connection Plate". Service and Repair Then continue with BB17.
BB17 Programming Combined Instrument Panel:
Program the control module with the values previously read off the combined instrument panel control module. Then continue with BB18.
NOTE: For information see "Reading Off and Programming Combined Instrument Panel".
BB18 Verification:
After carrying out the repair check that the fault has been remedied.
- Ignition off.
- Reconnect connectors, reinstall components.
- Connect combined instrument panel.
- Test drive the car at speeds above 20 km/h (12 mph), or lift up the front suspension and remove both front wheels.
WARNING: Test drive cars with AWD at a speed above 20 km/h (12 mph), or lift up the front and rear suspension and remove all wheels.
NOTE: When the rear wheels are stationary and the front wheels rotate, diagnostic trouble codes (DTCs) may be stored in the ABS system. Erase any diagnostic trouble codes (DTCs) stored in the ABS system after fault-tracing. Additionally, ensure that the front wheels are not rotating when the gear selector is moved.
- Ignition off.
- Disconnect the Volvo Scan Tool (ST) from the VADIS station. Use it as a stand alone tool and connect it to the data link connector (DLC) in the car.
- Ignition on.
- Read off the diagnostic trouble code (DTC) counters. Is counter value greater than 0?
Yes: Fault corrected
No: Fault not found
BB19 Faulty Signal, Intermittent Fault:
- Check fuel level sensor for an intermittent open-circuit and an intermittent short-circuit to supply voltage.
- Check combined instrument panel connector A and fuel level sensor connector for loose connections according to ZB5, and contact resistance and oxidation according to ZB6.
- Check cables between combined instrument panel: # A4 and # A5 and fuel level sensor for an intermittent open-circuit according to ZB2 and an intermittent short-circuit to supply voltage according to ZB4. Intermittent Faults