2016 Subaru BRZ Series.HyperBlueFACTORY OEM SERVICE PROCEDURE

Unit Inspection

  1. Fuel sender gauge Assembly check (fuel sender gauge main)
    1. Visual inspection
      1. Check the fuel sender gauge Assembly for damage.
      2. Check the dimensions between the float and fuel tank seating surface when the float is at F (upper limit) and E (lower limit).

        Dimension

        Float position F (upper limit) - fuel tank seating surface 121 to 129 mm {4.76 to 5.08 in}
        Float position E (lower limit) - fuel tank seating surface 14.7 to 22.7 mm {0.579 to 0.894 in}
        Fig 1: Checking Fuel Tank Seating Surface To Float Position Dimension
        G10213549Courtesy of SUBARU OF AMERICA, INC.
    2. Resistance check
      WARNING: Be careful of fire.
      1. Check that the float moves smoothly between the positions F (upper limit) and E (lower limit).
      2. Check the resistance between the connector terminals when the float is at F (upper limit) and E (lower limit). Also check that the resistance varies continuously.

        Resistance

        Inspection terminals Inspection conditions Standard value
        1 - 2 Float position F (upper limit) 6.5 to 8.5 Ξ©
        Float position E (lower limit) 168 to 172Ξ©
        Fig 2: Checking Fuel Sender Gauge Assembly Resistance
        G10213550Courtesy of SUBARU OF AMERICA, INC.
  2. Fuel sender gauge Assembly No. 2 check (fuel sender gauge sub)
    1. Visual inspection
      1. Check the fuel sender gauge Assembly No. 2 for damage.
      2. Check the dimensions between the float and fuel tank seating surface when the float is at F (upper limit) and E (lower limit).

        Dimension

        Float position F (upper limit) - fuel tank seating surface 148.8 to 157.8 mm {5.86 to 6.21 in}
        Float position E (lower limit) - fuel tank seating surface -1.3 to 7.7 mm {-0.05 to 0.30 in}
        Fig 3: Checking Float To Fuel Tank Seating Surface Dimension
        G10213551Courtesy of SUBARU OF AMERICA, INC.
    2. Resistance check
      WARNING: Be careful of fire.
      1. Check that the float moves smoothly between the positions F (upper limit) and E (lower limit).
      2. Check the resistance between the connector terminals when the float is at F (upper limit) and E (lower limit). Also check that the resistance varies continuously.

        Resistance

        Inspection terminals Inspection conditions Standard value
        1 - 2 Float position F (upper limit) 6.5 to 8.5 Ξ©
        Float position E (lower limit) 237.5 to 242.5 Ξ©
        Fig 4: Checking Fuel Sender Gauge Assembly No. 2 Resistance
        G10213552Courtesy of SUBARU OF AMERICA, INC.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • β€’ You smell fuel, burning insulation, or see smoke.
  • β€’ Brakes feel soft, pull hard to one side, or make grinding noises.
  • β€’ The engine overheats, stalls repeatedly, or misfires under load.
  • β€’ You are missing required tools, torque specs, or safe lifting equipment.
  • β€’ You are not confident in the next step or safety outcome.