Fuel Gauge Sender: Testing and Inspection

Fuel Gauge Sending Unit Test/Replacement

Special Tools Required
Fuel sender wrench 07AAA-SOXA100

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

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 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 OK, go to step 6.
- If the voltage is not OK, 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 Ohm resistor between 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 does not move, 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; the fuel level is continuously indicated even when the ignition switch is OFF, and the pointer moves more slowly than on other gauges.

9. Turn the ignition switch OFF.
10. Remove the fuel tank.
11. Disconnect the quick-connect fittings from the fuel pump.




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




13. 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 following readings, replace the fuel gauge sending unit.
14. If the resistance is not as specified, replace the fuel gauge sending unit.