Contents: Examination ⇓ Replacement ⇓
Caution! Gasoline is highly flammable, so take all fire safety precautions when working with any component of the fuel system. See the warning at the beginning of paragraph 2.
Examination
1. Disconnect the negative cable from the battery.
Warning. If your vehicle's audio system is equipped with anti-theft protection, make sure you have the unlock code before disconnecting the battery.
2. Remove the fuel pump together with the fuel level sensor from the fuel tank (see paragraph 5).
3. Using an ohmmeter, measure the resistance of the sensor at the connector. Measure the resistance with the float fully lowered (the tank is empty) and fully raised (the tank is full). The resistance should change smoothly.
4. When the tank is almost empty, the sensor resistance should be the highest (approximately 105 ohms).
5. When the tank is full, the sensor resistance should be very low - from 3 to 6 Ohms (Mazda) or 7 Ohms (Ford).
6. If the resistance differs from the specified values, replace the sensor.
Replacement
7. Disconnect the negative cable from the battery.
Warning. If your vehicle's audio system is equipped with anti-theft protection, make sure you have the unlock code before disconnecting the battery.
8. Remove the fuel pump together with the fuel level sensor from the fuel tank (see paragraph 5).
9. Disconnect the sensor connector from the base of the unit (figure 6.9).
10. Loosen the screws securing the sensor and remove it from the bracket (figure 6.10).
11. The sensor is installed in reverse order. Install a new gasket under the flange.