Cougar/XR7 V8-4.6L VIN W (1997)
Fuel Gauge: Description and Operation
NOTE: The fuel gauge and instrument cluster gauge amplifier are calibrated together when produced, and both units must be replaced when either is
replaced. The service kit contains a new fuel gauge and instrument cluster gauge amplifier.
The fuel level indication system is a magnetic-type indicating system, which consists of:
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fuel level sensor (part of fuel pump module) located in fuel tank.
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fuel gauge (located in instrument cluster).
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instrument cluster gauge amplifier (located in back of instrument cluster.)
Fuel Gauge
CAUTION: Do not remove gauge pointers; they cannot be recalibrated.
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The magnetic fuel gauge consists of four primary coils, one of which is wound at a 90-degree angle to the other three.
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The coils form a magnetic field which varies in direction according to the variable resistance of the fuel level sensor.
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A primary magnet, to which a shaft and pointer are attached, rotates to align to this primary field, resulting in pointer position.
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The bobbin / coil assembly is pressed into a metal housing which has two holes for dial mounting.
The fuel level sensor (part of the fuel pump module) changes resistance according to the level of fuel in the fuel tank, which varies the current flow
through the gauge. The pointer position varies proportionately to the current flow.
The pointer of the magnetic gauge remains in relatively the same position when the ignition switch is turned to OFF position.
There is no adjustment, calibration or maintenance required for the fuel gauge.
Low Fuel Level Warning Low Fuel Level Warning Switch
NOTE: The fuel gauge and instrument cluster gauge amplifier are calibrated together when produced, and both units must be replaced when either is
replaced. The service kit contains a new fuel gauge and instrument cluster gauge amplifier.
The instrument cluster gauge amplifier operates in the following manner:
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It provides a delay to the fuel gauge to prevent the fuel gauge pointer from fluctuating as a result of excessive movement in the fuel tank.
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The instrument cluster gauge amplifier is a small printed circuit board which latches into a pocket on the back of the instrument cluster.
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The electrical connections for ignition, ground, input from fuel pump module and output to fuel gauge are made through a spring-type connector
on the instrument cluster gauge amplifier to the instrument cluster printed circuit on the instrument cluster.
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There are no provisions for calibration or adjustment of the instrument cluster gauge amplifier.
