Fuel Gauge Sender: Testing and Inspection

Fuel Gauge Sending Unit Test

Special Tools Required
Fuel sender wrench 07AAA-001A100

NOTE: This article has been updated as per TSB SN030209.

NOTE: For the fuel gauge system circuit diagram, refer to the Gauges Circuit Diagram.

1. Check the No.9 BACK UP LIGHT INSTRUMENT LIGHT (10 A) fuse in the driver's under-dash fuse relay box before testing.
2. Turn the ignition switch OFF.
3. Remove the driver's side second row seat.





4. Cut the carpet at the dotted line.

NOTE: Be careful not to cut the wire harness that is under the carpet.

5. Remove the access panel (A) from the floor, then disconnect the fuel pump 5P connector (B).





6. Measure voltage between fuel pump 5P connector terminals No.1 and No.2 with the ignition switch ON (II). There should be battery voltage.
- If the voltage is as specified, go to step 7.
- If the voltage is not as specified, check for:
- an open in the YEL/BLU or BLK wire.
- poor ground (G502).

7. Turn the ignition switch OFF. Remove the No.13 BACK UP (7.5 A) fuse from the passenger's underhood fuse/relay box for at least 10 seconds, then reinstall it.





8. Install a 2 Ohms resistor between fuel pump 5P connector terminals No.1 and No.2, then turn the ignition switch ON (II).
9. Check that the pointer of the fuel gauge indicates "F".
- If the pointer does not indicate "F", replace the gauge.
- If the pointer indicates "F", inspect the fuel gauge sending unit, then go to step 10.

NOTE: The pointer of the fuel gauge returns to the bottom of the gauge dial when the ignition switch is OFF, regardless of the fuel level.

10. Relieve the fuel pressure.
11. Remove the fuel fill cap.
12. Disconnect the quick-connect fittings from the fuel pump.





13. Using the tool, loosen the fuel tank unit locknut (A).








14. Measure resistance between the No.1 and No.2 terminals with the float at E (EMPTY), 1/2 (HALF FULL), and F (FULL) positions.
If you do not get the above readings, replace the fuel gauge sending unit.

NOTE: Remove the No.13 BACK UP (7.5 A) fuse from the passenger's under-hood fuse/relay box for at least 10 seconds after completing troubleshooting, otherwise it may take up to 20 minutes for the fuel gauge to indicate the Correct fuel level.