NHTSA ID Number: 10126555
Manufacturer Communication Number: FSB 386-005
TSB/Document Date: 2017-12-22
Summary
Fuel Level Sending Unit Interference
Volvo Trucks
North
America
Greensboro, NC USA
Field Service Bulletin
Trucks
Date
12.2013
Group
No.
386 005
Release
Page
01
1(8)
Fuel Level Sending Unit Interference
VN, VHD, VAH
FSB 386-005, Fuel Level Sending Unit Interference
(December 2013)
Some Volvo trucks built prior to Feb. 17th, 2014 with round 26” fuel tanks, a straight shaft fuel
level sending unit and factory equipped fuel tank anti-siphons and/or cab parking heater fuel
pickup tube may experience fuel level sending unit float interference.
To address this float interference trucks built on or after February 17th 2014 with a 26" fuel
tank will be manufactured with fuel level sending unit 21451772 which incorporates a angled
shaft and a positive float stop.
If a truck equipped with a factory anti-siphon and/or a factory cab heater with tank mounted
pickup tube is experiencing erratic fuel levels, sticking fuel levels or complaints of inaccurate/
inconsistent fuel level readings; perform one of the following procedures to stop float level
interference issues.
Note: Trucks equipped with a fuel tank anti-siphon should always have the fuel tank filler cap
retaining chain oriented away from or opposite the fuel level sending unit before tightening the
fuel tank filler cap. To achieve this rotate the anti-siphon in the filler neck as needed.
A. Check and Adjust Parking Heater Tube, Replace Sending Unit
B. Check and Replace Parking Heater Tube, Replace Sending Unit (Tank on Vehicle)
C. Check and Replace Parking Heater Tube, Replace Sending Unit (Tank off Vehicle)
W3086127
1. 35° – 45°
PV729-FSB386-005_V
USA62104
Volvo Trucks North America
Field Service Bulletin
Date
12.2013
Group
No.
Release
386
005
01
Repair Procedure
Note: Information is subject to change without notice.
Illustrations are used for reference only, and may differ slightly from the actual engine
version. However, key components addressed in this information are represented as
accurately as possible.
You must read and understand the precautions and guidelines in Service Information,
group 30, "General Safety Practices, Electrical and Electronics" before performing this
procedure. If you are not properly trained and certified in this procedure, ask your
supervisor for training before you perform it.
Repair A
Check and Adjust Parking Heater Tube
1 Secure the vehicle for service by parking it on a flat level surface, applying the parking
brake, chocking the rear wheel, and placing the transmission in neutral.
2 Disconnect all cables from the negative battery terminals to prevent personal injury from
electrical shock and prevent damage to electrical components.
3 Check parking heater tube for proper clocking.
Note: Some models will require the side fairing or other components to be removed for
accessibility.
W3086131
Incorrect
W3086132
Correct
4 Loosen the flare nut and clock the fuel pick-up tube to the correct position.
Note: You may need to remove and adjust cable tie to relieve stress on the fuel hose in
order to position correctly.
5 Secure parking heater tube. Tighten to 12 ± 1 Nm (110± 10 in lb).
If the parking heater fuel pickup tube will not torque properly or is stripped, perform repair B or
C if tank removal is necessary to replace the parking heater pickup tube.
Page
2(8)
Volvo Trucks North America
Field Service Bulletin
Date
12.2013
Group
No.
Release
386
005
01
Fuel Sending Unit, Replace
Note: In most cases, the sending unit can be removed from the current position on truck
without removing the fuel tank.
1 Remove the harness connector.
2 Cut cable tie(s) as needed.
3 Mark the harness position with a marker on the fuel tank before removing sender.
4 Remove screws securing sending unit to tank.
5 Remove sending unit according to the following steps:
a. Pull sending unit up and out of tank until the float can be touched
b. Grab float with one finger and hold.
c. Slide sending unit back into tank a short distance.
d. Maneuver fingers and pull float out of tank.
e. Lift the sending unit out of the tank at an extreme angle to clear the cab floor.
6 Install new sending unit (21451772) and gasket in reverse order of removal.
7 Orientate sending unit to prior mark made on tank.
8 Secure sending unit with screws. Tighten to 6 ± 1 Nm (53 ± 9 in lb).
9. Connect battery cables.
Page
3(8)
Volvo Trucks North America
Field Service Bulletin
Date
12.2013
Group
No.
Release
386
005
01
Repair B (Tank on Vehicle)
Only perform this repair if Fuel Pick-up Tube flair nut is stripped.
Parking Heater, Fuel Pickup Tube, Check
1 Secure the vehicle for service by parking it on a flat level surface, applying the parking
brake, chocking the rear wheel, and placing the transmission in neutral.
2 Disconnect all cables from the negative battery terminals to prevent personal injury from
electrical shock and prevent damage to electrical components.
3 Check the parking heater tube for proper clocking and the flare nut for over torquing or
stripped threads.
Note: Some models will require the side fairing or other components to be removed for
accessibility.
W3086131
Incorrect
W3086132
Correct
Page
4(8)
Volvo Trucks North America
Field Service Bulletin
Date
12.2013
Group
No.
Release
386
005
01
Fuel Sending Unit and Fuel Pickup Tube Replace
Note: In most cases, the sending unit can be removed from the current position on truck
without removing the fuel tank.
1. Remove the harness connector.
2. Cut cable tie(s) as needed.
3. Mark the harness position with a marker on the fuel tank before removing sender.
4. Remove screws securing sending unit to tank.
5. Remove sending unit according to the following steps:
a. Pull sending unit up and out of tank until the float can be touched
b. Grab float with one finger and hold.
c. Slide sending unit back into tank a short distance.
d. Maneuver fingers and pull float out of tank.
e. Lift the sending unit out of the tank at an extreme angle to clear the cab floor.
6. Install new sending unit (21451772) and gasket in reverse order of removal.
7. Orientate sending unit to prior mark made on tank.
8. Secure sending unit with screws. Tighten to 6 ± 1 Nm (53 ± 9 in lb).
9. Remove the clamp from the parking heater pickup tube.
10. Remove the hose from the pickup tube.
11. Loosen and remove the pickup tube and flare nut fitting.
12. Install new flare nut fitting and pickup tube. Clock the pickup tube to the correct position
and secure. Tighten to 12 ± 1 Nm (110± 10 in lb).
13. Install the hose and secure with clamp.
14. Connect battery cables.
Page
5(8)
Volvo Trucks North America
Field Service Bulletin
Date
12.2013
Group
No.
Release
386
005
01
Repair C (Tank off Vehicle)
Only perform this repair if tank removal is necessary to perform Parking heater Tube
Replacement.
Parking heater, fuel pickup tube, Check
1 Secure the vehicle for service by parking it on a flat level surface, applying the parking
brake, chocking the rear wheel, and placing the transmission in neutral.
2 Disconnect all cables from the negative battery terminals to prevent personal injury from
electrical shock and prevent damage to electrical components.
3 Check the parking heater tube for proper clocking and the flare nut for over torquing or
stripped threads.
Note: Some models will require the side fairing or other components to be removed for
accessibility.
W3086131
Incorrect
W3086132
Correct
Page
6(8)
Volvo Trucks North America
Field Service Bulletin
Date
12.2013
Group
No.
Release
386
005
01
Fuel Sending Unit and Fuel Pickup Tube Replace
1 Remove left side fairings.
Note: VNL only
2 Remove fasteners on rear support for fairing and remove.
Note: VNL only
3 Remove fasteners on top step, over fuel tank and remove step.
4 Drain fuel from tank.
5 Disconnect fuel lines and harness.
6 Position jack to support weight.
7 Remove fasteners on tensioning bands and remove.
8 Remove fuel tank.
9 Loosen and remove the pickup tube and flare nut fitting.
10 Install new flare nut fitting and pickup tube. Clock the pickup tube to the correct position
and secure. Tighten to 12 ± 1 Nm (110± 10 in lb).
11 Mark the harness position with a marker on the fuel tank before removing sender.
12 Remove screws securing sending unit to tank.
13 Remove sending unit.
14 Install new sending unit (21451772) and gasket.
Note: Orientate sending unit to prior mark made on tank.
15 Secure sending unit with screws. Tighten to 6 ± 1 Nm (53 ± 9 in lb).
16 Install fuel tank in place with floor jack.
17 Install tensioning bands, while ensuring that all insulators are in position upon tank
installation. Tighten to 75 ± 7 Nm (55 ± 5 in lb).
18 Remove jack support.
19 Reconnect fuel lines, and harness.
20 Pump fuel into tank.
21 Reinstall rear fairing support and secure with fasteners.
Tighten to 24 ± 4 Nm (18± 3 ft lb).
22 Reinstall left side fairings.
Note: VNL Only
23 Install top step over fuel tank and secure with fasteners.
Tighten to 24 ± 4 Nm (18 ± 3 ft lb).
24 Connect all previous removed cables from batteries.
25 Check for any fuel leaks.
Page
7(8)
Volvo Trucks North America
Field Service Bulletin
Date
12.2013
Group
No.
Release
386
005
01
Page
8(8)
Reimbursement
This repair may be eligible for reimbursement if a product failure was experienced within time and mileage limits of
the applicable Warranty coverage. Reimbursement is obtained via the normal claim handling process.
Claim Type (used only when uploading from the Dealer Bus. Sys.)
W
Labor Code
Repair A
Primary Labor Code
includes Checking Time
38201–0–01
0.3 hrs.
Repair B
Primary Labor Code
includes Checking Time
38201–0–02
0.4 hrs.
Repair C
Primary Labor Code
includes Checking Time
38201–0–03
1.5 hrs.
Causal Part
21451760
Volvo Trucks North America engages in a comprehensive program of testing and evaluating
to provide the best possible product. Volvo Trucks North America however, is not committed
to, or liable for updating existing vehicles.
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TSB/Document ID: FSB 386-005
Replacement Service Bulletin Number:
MFR Communication Date: 2013-12-11
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL SYSTEM, OTHER:STORAGE:FUEL GAUGE SYSTEM
MFR Component System:
MFR Component Subsystem:
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