Problems fixed: Chrysler, Kia and Mini

What’s in this article] Leading technical supplier Autodata helps you fix three common problems found in passenger cars

The problem

A customer's Chrysler Grand Voyager is in for a routine service and they have complained that the fuel filler nozzle continuously cuts out when re-fuelling the vehicle. We have experienced the fault when re-fuelling and have visually checked the fuel filler pipe for blockages but we can’t find the source of the fault.

The fix

It’s a fault found on some Grand Voyager models produced up to late February 2008. The cause is due to a kinked or restricted fuel tank ventilation pipe. Locate the fuel tank ventilation pipe on top of the fuel tank, inspect for damage and replace it if necessary Re-fuel the vehicle to ensure the fault has been resolved.

The problem

A 2016 Kia Sorento 2.2 diesel has its fuel low level warning lamp illuminated but the fuel tank isn’t empty. The fuel gauge tank sensor seems to be in good working order and we think it could be the instrument panel at fault but are reluctant to replace it as it’s an expensive part.

The fix

This problem affects some Sorento models produced between 2015-16 with the D4HB engine code. The cause is due to an unsatisfactory design of the fuel gauge tank sensor. Remove the sensor from the fuel tank. Check the colour of the fuel gauge tank sensor float arm, and, if the fuel gauge tank sensor float arm mounting is coloured blue, fit a modified fuel gauge tank sensor. If necessary, re-fuel vehicle to ensure the fault has been resolved.

The problem

A customer is complaining of an abnormal noise when the clutch pedal is depressed in their 2006 Mini. We can hear the noise when operating the clutch pedal but can’t find the source of the fault.

The fix

The noise is due to excessive friction between the clutch pedal and clutch pedal return spring. Modify the clutch pedal by fitting a clutch pedal return spring bush available from Mini parts department and then carry out a road test to ensure the noise has been eliminated.