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Test B: Fuel Gauge Inaccurate

  1. Test fuel gauge. See FUEL GAUGE  under COMPONENT TESTS. If fuel gauge is okay, go to next step. If fuel gauge tests bad, replace fuel gauge.
  2. Test fuel level sensor. See FUEL LEVEL SENSOR  under COMPONENT TESTS. If fuel level sensor is okay, repair Black/Green wire between ground and fuel level sensor harness connector. See WIRING DIAGRAMS. If level sensor tests bad, replace fuel level sensor. If problem is not resolved, go to next step.
  3. Turn ignition off. Remove instrument cluster. See INSTRUMENT CLUSTER  under REMOVAL & INSTALLATION. Disconnect instrument cluster harness connector C254. See Figure . Measure resistance between ground and instrument cluster harness connector C254 terminal No. 5 (Black/Green wire). Resistance should be less than 5 ohms. If resistance is less than 5 ohms, go to next step. If resistance is more than 5 ohms, repair open in Black/Green wire between instrument cluster harness connector and ground. See WIRING DIAGRAMS  .
  4. Turn ignition off. Disconnect fuel level sensor and pump connector. Measure resistance of Yellow/Brown wire between instrument cluster harness connector C254 terminal No. 4, fuel level sensor and pump harness connector terminal No. 3. See Figure and Figure . Resistance should be less than 5 ohms. If resistance is less than 5 ohms, go to next step. If resistance is more than 5 ohms, repair open in Yellow/Brown wire. See WIRING DIAGRAMS  .
    Fig 1: Identifying Fuel Level & Pump Harness Connector
    G97D28053Courtesy of FORD MOTOR CO.
  5. Turn ignition on. Measure voltage between ground and instrument cluster harness connector C254 terminal No. 6 (Black/Yellow wire). Voltage should be more than 10 volts. If voltage is more than 10 volts, go to next step. If voltage is less than 10 volts, repair Black/Yellow wire between METER fuse and instrument cluster harness connector. See WIRING DIAGRAMS  .
  6. Visually inspect instrument cluster printed circuit for damage, cracks or hot spots. If instrument cluster printed circuit is okay, replace fuel gauge and retest system. If vehicle is equipped with fuel/temp gauge assembly, replace instrument cluster gauge amplifier. See INSTRUMENT CLUSTER GAUGE AMPLIFIER  under REMOVAL & INSTALLATION.
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