incorrect fuel-gauge reading? 1996 caravan 3.3

Hi all,

I have a 1996 Caravan with a 3.3L.

According to the manual it's suppose to have a 75L gas tank. Which I believe however if I leave the gas gauge go down to the point where I get my warning light (or even past that) when I fill up the tank I'm only squeazing in 50 to 55 litres. Does this make sense? Does this mean I still have 20 to 25 litres of gas left? I was thinking of driving it until it actually ran out of gas however since my wife drives it %90 of the time I didn't want to chance it. :p

What could be the cause of this incorrect reading? The gauge in the tank? Is this something I can replacing easily or adjust? (without it coasting me an arm and a leg)

thxs
-JG

NO: 14-02-96
SUBJECT: Fuel Tank Service Information/Fuel Gauge Accuracy/Fuel Tank Capacity
DATE: May 3, 1996
NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-08-95 REVISION A, DATED JAN. 26, 1996, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1995 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-96084). THE VEHICLES INVOLVED, PARTS REQUIRED, DIAGNOSIS AND REPAIR PROCEDURE ARE REVISED.

INFORMATION IS ALSO PROVIDED ON HOW TO SERVICE VEHICLES THAT HAVE OR HAVE NOT HAD RECALL 665 OR 670 PERFORMED ON THEM. THIS IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN USED.

DISCUSSION:
The following items are service procedure clarifications for the 1996 NS vehicle build and service variations:

VEHICLES INVOLVED IN RECALL #665 THAT REQUIRE FUEL TANK REPLACEMENT AFTER RECALL #665 HAS BEEN PERFORMED: Must have vapor canister hose harnesses (that were added as part of the recall service) removed. The new fuel tank will include revised rollover valves and a new vapor canister harness that can be attached directly to the metal chassis tube to the vapor canister. Cap the two open filler tube nipples (upper and lower rollover valve nipples on the filler tube as shown on page 10 Figure 14 of recall #665) with vacuum cap P/N 3580172.

VEHICLES INVOLVED IN RECALL #665 THAT HAVE HAD THE FUEL TANK REPLACED BEFORE RECALL #665 HAS BEEN PERFORMED: Only require the installation of the filler tube ground strap. The new fuel tank includes revised rollover valves and therefore does not require the added recall filler tube/rollover valve assembly. Use parts package and the service procedure for Recall #670 to install a filler tube ground strap. Dealers are to submit the recall claim using the labor operation number 14-66-51-82 to record service completions for Recall #665 and to provide dealer payment.

VEHICLES INVOLVED IN EITHER RECALL #665 OR #670 THAT HAVE BEEN MODIFIED AND NO LONGER HAVE THE ORIGINAL FUEL TANKS: Still require the installation of the filler tube ground strap. Use the parts package and the service procedure for Recall #670 to install a filler tube ground strap. Dealers are to submit the recall claim using labor operation number for the recall that the vehicle is involved in to record the service completions and to provide dealer payment.

THE EXTRA 3/8" VENT TUBE RETAINER (SUPPLIED IN THE RECALL #665 PARTS PACKAGES) MAY BE TOO LONG FOR SOME OF THE INVOLVED VEHICLES: A change in production was made to the length of the retainer. Therefore, if the 3/8" retainer from the recall package can not be assembled, reuse the original retainer.

SYMPTOM/CONDITION:
Only 12-13 gallons of fuel are able to be added when the low fuel warning light first comes "ON" (normal is 16-17) or 15-16 gallons of fuel are able to be added when the fuel gauge reads "E" (normal is 18-20).

DIAGNOSIS:
Inspect the bottom of the fuel tank. If the fuel tank bottom is bowed upward or the "short fill" condition has otherwise been verified, perform the Repair Procedure.

PARTS REQUIRED:
Quantity
Part No.
Description

1

4883140
Tank, Fuel

1

4695227
O-Ring, Fuel Pump Module

1

4883322
Spacer, Fuel Level Unit



REPAIR PROCEDURE:
This bulletin involves installing a spacer on the fuel level unit and IF the bottom of the fuel tank is bowed upward installing a revised fuel tank.

Perform the appropriate fuel system pressure release procedure described on page 14-9 of the 1996 Town & Country, Caravan And Voyager Service Manual (Publication No. 81-370-6105).
Drain the fuel tank into an approved gasoline holding tank.
Record the radio station presets, disconnect and isolate the negative battery cable.
Raise the vehicle on an appropriate hoist.
Use a transmission jack to support the fuel tank. Remove the attaching bolts from the fuel tank retaining straps. Lower the tank slightly.
Clean the area around the fuel pump module and tank to prevent foreign material from getting into the fuel tank.
Disconnect the fuel lines from the fuel pump module by depressing the quick connect retainers with thumb and fore finger.
Slide the fuel pump module electrical connector lock to the unlocked position. Push down on the connector retainer and pull the connector from the module.
Using Special Tool 6856, turn the plastic lock nut counterclockwise to release the fuel pump module.
Remove the fuel pump module from the fuel tank. Cut and discard the O-ring seal.
Depress the retaining tab and remove the fuel pump/level sensor wiring connector from the electrical connector at the bottom of the fuel pump module mounting flange.
Insert a screwdriver between the fuel pump module and the top of the fuel level sensor housing. Push the fuel level sensor down slightly.
Slide the fuel level sensor out of the installation channel of the module.
Slide spacer P/N 4883322 into the installation channel so its "V"-shaped channel is on the wire side of the installation channel and the "V"-shaped channel of the spacer captures the fuel level sensor wires. The spacer should slide all the way to the top end of the installation channel.
Make sure the fuel level sensor wires are routed in the slot at the top of the back side of the fuel level sensor, then slide the fuel level sensor up into the installation channel until it "snaps" into place. Be sure the tab at the bottom of the sensor locks in place and the spacer is tight between the fuel pump module body and the fuel level sensor.
Connect the fuel pump/level sensor wiring connector to the fuel pump module.
NOTE: IF THE BOTTOM OF THE FUEL TANK IS NOT BOWED UPWARD SKIP TO STEP 25.

Remove the three screws attaching the filler tube blocker and separate the blocker from the vehicle.
Disconnect the rollover valve harness to steel vent tube connection at the front of the tank.
Disconnect the fuel filter supply line from the steel fuel supply line.
Loosen the clamp on the filler tube hose at the tank connection.
Carefully remove the filler tube hose from the fuel tank.
Disconnect the filler vents from the filler tube by squeezing the retainer and pulling the connector off of the steel tube.
Lower the fuel tank slowly while feeding the vent lines through the frame rail to remove the fuel tank from the vehicle.
Remove the fuel filter attaching screw and transfer it and the fuel filter to the revised fuel tank (P/N 4883140). Torque the screw to 35-45 in. lbs. (4-5 Nm).
Insure the seal area of the fuel tank that is to be used is clean and install the fuel pump module into the tank using a new O-ring seal (P/N 4695227). Make sure the locating tab on the fuel pump module is lined up with the notch on the fuel tank.
Torque the fuel pump module lock nut to 40-45 ft. lbs. (54-61 Nm) using Special Tool 6589.
Attach the fuel filter lines to the fuel pump module by pushing the fittings onto the tubes until the retainers seat. Pull back on the connectors to make sure they are secure.
NOTE: IF THE FUEL TANK WAS NOT REPLACED, SKIP TO STEP 30.

Place the revised fuel tank on a transmission jack and slowly raise it into position while feeding the fuel filler vent lines through the frame rail. Make sure the vent lines are not crossed on top of the fuel tank.
Line up the fuel filler tube hose with the fuel tank inlet neck and push it on.
Raise the tank up to the underbody and install the fuel tank retention straps. Torque the fasteners to 30-50 ft. lbs. (40-68 Nm).
NOTE: IF THE FUEL TANK WAS NOT REPLACED, SKIP TO STEP 36.

Attach the filler vent lines to the filler tubes by pushing the connectors on until they are seated. Pull back on the connectors to make sure they are secure.
Torque the fuel filler tube hose clamp at the fuel tank to 25-35 in. lbs. (3-4 Nm).
Push the fuel filter supply line connector onto the steel fuel supply line until it is seated. Pull back on the connectors to make sure they are secure.
Attach the rollover valve harness hose to the steel vent tube at the front of the fuel tank.
Install the fuel filler tube blocker and torque the fasteners to 45-55 in lbs. (5-6 Nm).
Attach the fuel pump module electrical connector.
Lower the vehicle and refuel it with fuel drained into an appropriate holding tank in step 2.
Connect the negative battery cable.
Program the radio station presets and set the clock.

you probaly just need to replace you fuel level sending unit but the tank needs to be lowered to replace the sending unit

wow.. long reply ;)
so from what I gather there was a recall for this exact issue? Should I be calling dodge and asking if this was done to my van? I bought my van used this year so I have no idea if this was done or not. Is there a specific place I should be calling?

If it's only the fuel level sending unit is that something hard to replace? I replaced the fuel filter this summer and had to lower the gas tank a little to access it.. wasn't that difulcult. Any idea on pricing?

thxs for the help

bump bump please :)

anybody else have any inputs for this old thread? Before I start replacing parts I want to make sure I'm on the right track.

Thanks

for recalls do I just call a local dealer to see if he can perform the work? or is there a Dodge 800 phone number I have to call first? (btw I'm in Canada)

Thanks
-JG

Go to your local dealer give them your vin# and they can tell you what recalls were issued and what was fixed on your vehicle.

well I went to my local dealer (here in Canada) and there was 5 recalls that needed to be performed on my van. To my amazement the recall posted in this thread wasn't one of them. How can this be if the symtoms described are the axact ones I'm having? Could there be an error in Chrysler Canada's database? I strongly believe my caravan's gas tank needs to be replaced.

:(

Try to call Chrysler Canada and ask them about the recalls and tell them about your problem. Also mention to them that you are aware of the recall about your fuel tank.