Fuel Tank Unit: Testing and Inspection
Fuel Gauge Sending Unit Test
Test
1. Fuel Gauge Sending Unit - DTC Check
1. Check the No. B5 IG1 METER (10 A) fuse in the under-dash fuse/relay box before testing.
2. Check for body electrical system DTCs.
* If no DTCs are found, go to the next procedure.
* If DTC B1175 or B1176 is indicated, go to the indicated DTC's troubleshooting.
Removal
1. Fuel Gauge Sending Unit Access Panel
1. Remove the access panel (A) from the floor.
2. Disconnect the connector (B).
Test
1. Fuel Gauge Sending Unit Harness
1. Measure the voltage between fuel tank unit 4P connector terminals No. 2 and No. 4 with the ignition switch turned to ON (II). There should be battery voltage.
* If the voltage is OK, turn the ignition switch to LOCK (0), and go to the next procedure.
* If the voltage is not as specified, turn the ignition switch to LOCK (0), and check for:
- a short in the YEL wire to ground.
- an open in the YEL or PUR wire.
2. Connect the connector to the fuel tank unit.
Removal
1. HDS DLC - Connection
1. Connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard.
2. Turn the ignition switch to ON (II).
3. Make sure the HDS communicates with the vehicle. If it does not communicate, go to the DLC circuit troubleshooting.
2. Fuel Pump Off
1. From the INSPECTION MENU of the HDS, select Fuel Pump OFF, then start the engine, and let it idle until it stalls.
NOTE:
* Do not allow the engine to idle above 1,000 rpm or the PCM will continue to operate the fuel pump.
* Pending or Confirmed DTC may be set during this procedure. Check for DTCs, and clear them as needed.
2. Turn the ignition switch to LOCK (0).
3. Battery Terminal - Disconnection
1. Make sure the ignition switch is in LOCK (0).
2. Disconnect and isolate the negative cable (A) from the battery.
NOTE: Always disconnect the negative side first.
3. Disconnect the positive cable (B) from the battery.
4. Fuel Fill Cap
1. Remove the fuel fill cap to relieve the pressure in the fuel tank.
5. Fuel Pressure - Relieving (Fuel Tank Unit)
NOTE: Before you work on the fuel lines and fittings, read the Fuel Line/Quick-Connect Fitting Precautions. Service Precautions
1. Check the fuel quick-connect fitting for dirt, and clean it if needed.
2. Place a rag or shop towel (A) over the quick-connect fitting.
3. Disconnect the quick-connect fitting: Hold the connector (A) with one hand, and squeeze the retainer tabs (B) with the other hand to release them from the locking tabs (C). Pull the connector off.
NOTE:
* Be careful not to damage the line (D) or other parts.
* Do not use tools.
* If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes off easily.
* Do not remove the retainer from the line; once removed, the retainer must be replaced with a new one.
6. Fuel Tank Unit
1. Using the special tool, loosen the locknut (A).
2. Remove the locknut (A).
3. Remove the fuel tank unit (B).
Test
1. Fuel Gauge Sending Unit - Test
1. Measure the resistance between fuel tank unit connector terminals No. 2 and No. 4 with the float at E (EMPTY), LOW (LOW FUEL INDICATOR), 1/2 (HALF FULL), and F (FULL) positions.
If you do not get the following readings, replace the fuel gauge sending unit.
2. Reconnect the fuel tank unit connector.
3. Remove the No. A29 BACK UP (10 A) fuse from the under-hood fuse/relay box for at least 10 seconds, then reinstall it.
4. Temporarily connect the battery positive and negative cables to the battery.
5. Turn the ignition switch to ON (II).
6. Check that the pointer of the fuel gauge indicates F with the float at F.
* If the pointer of the fuel gauge does not indicate F, replace the gauge control module.
* If the gauge is OK, the test is complete.
NOTE:
* The pointer of the fuel gauge returns to the bottom of the gauge dial when the ignition switch is turned to ACC (I) or LOCK (0), regardless of the fuel level.
* Remove the No. A29 BACK UP (10 A) fuse from the 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.
7. Turn the ignition switch to LOCK (0), then disconnect the battery negative and positive cables from the battery.
Installation
1. Fuel Tank Unit
1. Insert the fuel tank unit (A) partially into the fuel tank with a new O-ring (B).
2. Align the marks (A) on the fuel tank and fuel tank unit, then insert the fuel tank unit into the fuel tank until.
NOTE: To avoid a fuel leak, check the base gasket, visually or by hand, to make sure it is not pinched.
3. Tighten a new locknut (A) by hand holding the fuel tank unit vertically.
NOTE: Before tightening, align the mark (B) on the locknut to the start of the thread (C).
4. Using the special tool, tighten the locknut to the specified torque.
NOTE:
* After tightening, make sure the marks are still aligned.
* After installation, check the base gasket, visually or by hand, to make sure it is not pinched.
2. Fuel Line/Quick-Connect Fitting - Connection (Fuel Tank Unit)
NOTE: Before you work on the fuel lines and fittings, read the Fuel Line/Quick-Connect Fitting Precautions. Service Precautions
1. Connect the quick-connect fitting (A) to the fuel tank unit (B).
3. Fuel Gauge Sending Unit Access Panel
1. Connect the connector (A).
2. Install the access panel (B) to the floor.
4. Fuel Fill Cap
1. Install the fuel fill cap.
5. Battery Terminal - Reconnection
NOTE: If the battery performance is abnormal, test the battery.
1. Clean the battery terminals.
2. Connect the positive cable (A) to the battery.
NOTE: Always connect the positive side first.
3. Connect the negative cable (B) to the battery.
4. Apply multipurpose grease to the terminals to prevent corrosion.
6. Fuel Line Leak Check
1. Turn the ignition switch to ON (II) (but do not operate the starter motor). The fuel pump runs for about 2 seconds, and fuel pressure rises. Repeat this two or three times, then make sure there are no fuel leaks.