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Home >> Suzuki >> 2003 >> XL-7 Base, 4WD >> Repair and Diagnosis >> Engine Mechanical >> Fuel System >> Repair Instructions >> Fuel Tank Pressure and Temp. Sensor Inspection
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Fuel Tank Pressure and Temp. Sensor Inspection

  1. Remove fuel tank pressure and temp. sensor from fuel tank.
  2. Check sensor air vent hole and pressure passage for clog. Clean if clogged.
  3. Check sensor O-ring for damage and deterioration. Replace as necessary.
    Fig 1: Checking Sensor Air Vent Hole & O-Ring
    G01478926Courtesy of SUZUKI OF AMERICA CORP.
  4. Arrange 3 new 1.5 V batteries (2) in series (check that total voltage is 4.5 - 5.0 V) and connect its positive (+) terminal to "A" terminal of tank pressure and temp. sensor (1) and negative (-) terminal to "B" terminal. Then check voltage between "C" and "B".

    Also, check if voltage reduces when vacuum is applied up to 6.6 kPa (50 mmHg) by using vacuum pump (3) and if it increases when positive pressure applied up to 6.6 kPa (50 mmHg) by using hand pump.

    If measured voltage doesn't shown such characteristic as shown in the figure, replace fuel tank pressure and temp. sensor.

    CAUTION:
    • As connection to wrong terminal will cause damage to tank pressure and temp. sensor, make absolutely sure to connect properly as shown.
    • Do not apply pressure higher than 98 kPa (742 mmHg) to tank pressure and temp. sensor by hand pump. Applying excessive pressure will break it.
      Fig 2: Testing Fuel Tank Pressure Sensor
      G01478927Courtesy of SUZUKI OF AMERICA CORP.
  5. Immerse temperature sensing part (1) of fuel tank pressure and temp. sensor (2) in water (or ice) and measure resistance between sensor terminal "A" and "B" while heating water gradually.

    If measured resistance doesn't show such characteristic as shown in the figure, replace Fuel Tank pressure and temperature sensor.

    Fig 3: Testing Fuel Tank Temperature Sensor
    G01478928Courtesy of SUZUKI OF AMERICA CORP.