Fuel Gauge Sender: Testing and Inspection

Fuel Gauge Sending Unit Test/Replacement

Special Tools Required
Adjustable ring wrench 07XAA-001010A

NOTE: This article has been updated as per TSB SN030415.

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

Test
1. Check the No.6 fuse in the under-dash fuse/relay box before testing.
2. Remove the middle floor panel.
3. Remove the access panel from the floor.
4. Turn the ignition switch OFF, then disconnect the fuel pump 5P connector.




5. Measure voltage between the 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 6.
- If the voltage is not as specified, check for:
- an open in the YEL/BLK or BLK wire.
- poor ground (G502).

6. Turn the ignition switch OFF. Remove the No.18 (7.5 A) fuse from the under-dash fuse/relay box for at least 10 seconds, then reinstall it.




7. Install a 2 Ohms resistor between the fuel pump 5P connector terminals No.1 and No.2, then turn the ignition switch ON (II).
8. Check that the pointer of the fuel gauge starts moving toward the "F" mark.
- If the pointer of the fuel gauge does not move at all, replace the gauge.
- If the gauge is OK, inspect the fuel gauge sending unit.

NOTE:
- Turn the ignition switch OFF before the pointer reaches "F" on the gauge dial. Failure to do so may damage the fuel gauge.
- The fuel gauge is a bobbin (cross-coil) type, hence the fuel level is continuously indicated even when the ignition switch is OFF, and the pointer moves more slowly than that of a bimetal type.

Replacement
1. Remove the fuel tank.
2. Disconnect the quick-connect fittings from the fuel pump.




3. Using the tool, loosen the fuel pump locknut (A), and remove the fuel pump.




4. Measure the 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 given readings, replace the fuel gauge sending unit (A).




5. Install the pants in the reverse order of removal with a new base gasket and new quick connect retainers, then check these items:
- When connecting the wire harness, make sure the connection is secure and the connector (B) is firmly locked into place.
- Do not fold over the lower part of the suction filter (C).
- When installing the fuel gauge sending unit (A), make sure the connection is secure and the connector is firmly locked into place. Be careful not to bend or twist it excessively.