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Fuel Gauge Testing

  1. Disconnect fuel tank sending unit 6-pin connector. Fuel tank sending unit 6-pin connector is located on front of fuel tank. Using Gauge System Tester (Rotunda 021-00055), connect one lead to Yellow wire terminal of fuel tank sending unit 6-pin connector and other lead to ground. See TESTING FUEL GAUGE illustration.
  2. Set tester to specified resistance values. See FUEL GAUGE RESISTANCE VALUES SPECIFICATIONS table. Turn ignition on and check if needle indicator displays correct values. Continue inspection for 2 minutes on each setting to correctly judge accuracy of gauge.
  3. Allowable error is twice the width of fuel gauge needle. If fuel gauge readings are correct, go to FUEL GAUGE SENDING UNIT CHECK. If fuel gauge readings are not correct, replace instrument panel assembly.
Fig 1: Testing Fuel Gauge
G90G08301Courtesy of FORD MOTOR CO.
FUEL GAUGE RESISTANCE VALUES SPECIFICATIONS

Segments Resistance
1-10 Less Than 8
1-9 8-14
1-8 14-20
1-7 20-25
1-6 25-30
1-5 30-37
1-4 37-46
1-3 46-63
1-2 63-86
1 86-98