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Test B: Fuel Sender Open, Shorted Or Inaccurate

WARNING: This page is about a different car, the 2002 Lincoln Blackwood. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Fuel fills of 6 gallons or less require at least 5-20 minutes to update fuel gauge reading.
NOTE: After making any repairs, clear DTCs and perform self-test.
  1. Turn ignition switch to OFF position. Connect NGS tester to DLC connector. Turn ignition switch to ON position. Retrieve continuous DTCs from HEC. If DTC B1202 is received, go to step  6. If DTC B1204 is received, go to step  8. If no codes related to concern are received, go to next step.
  2. Turn ignition switch to RUN position. Using New Generation Star (NGS) tester, select instrument cluster FUEL LEVEL CONTROL active command. Trigger, observe and scroll FUEL LEVEL at 0%, 54% and 100%. Fuel gauge should indicate below "E" with 0%, half with 54% and full stop with 100%. If fuel gauge operates as specified, go to next step. If fuel gauge does not operate as specified, go to step  10.
  3. Turn ignition switch to LOCK position. Disconnect fuel pump assembly Black 4-pin harness connector C433. Connector C433 is located in center of vehicle near fuel tank. Connect one lead of Instrument Gauge System Tester (014-R1063), to fuel pump assembly harness connector C433 terminal No. 2 (Yellow/White wire) and the other tester lead to terminal No. 3 (Black/Orange wire). See Fig 1. Set instrument gauge system tester to 15 ohms. Turn ignition switch to RUN position. Wait 1-2 minutes. Fuel gauge should read below "E". Turn ignition switch to LOCK position. Set instrument gauge system tester to 145 ohms. Turn ignition switch to RUN position. Wait 1-2 minutes. Fuel gauge should read Full or more. If fuel gauge reads as indicated, go to next step. If fuel gauge does not read as indicated, go to step  6.
  4. Check fuel tank for any damage or deformation. If fuel tank is okay, go to next step. If fuel tank is damaged, replace fuel tank. See FUEL TANK under REMOVAL & INSTALLATION in REMOVAL, OVERHAUL & INSTALLATION article in ENGINE PERFORMANCE.
  5. Check fuel pump in-tank assembly mounting, float, float rod, wiring and connections for damage or obstruction. See REMOVAL, OVERHAUL & INSTALLATION - BLACKWOOD article in ENGINE PERFORMANCE. If fuel pump and wiring are okay, replace fuel sender. If fuel pump assembly and/or wiring is damaged, repair or replace fuel pump as necessary.
  6. Measure resistance in Yellow/White wire between terminal No. 2 at fuel pump assembly harness connector C433 and terminal No. 3 at instrument cluster harness connector C220b. See Figure and Fig 1 . Measure resistance between ground and instrument cluster 22-pin harness connector C220b terminal No. 3 (Yellow/White wire). Resistance should be 5 ohms or less between instrument cluster harness connector C220b and fuel sender harness connector C433, and more than 10 k/ohms between instrument cluster harness connector C220b and ground. If resistance is as specified, go to next step. If either resistances are not as specified, repair open or short to ground in Yellow/White wire between fuel pump assembly and instrument cluster. See WIRING DIAGRAMS .
  7. Turn ignition switch to ON position. Measure voltage between instrument cluster harness connector C220b terminal No. 3 (Yellow/White wire) and ground. If any voltage is present, repair short to power in Yellow/White wire and test system operation. If no voltage is present, go to next step.
  8. Turn ignition switch to OFF position. Disconnect instrument cluster harness connector C220b and fuel pump harness connector C433. Measure resistance between harness connector C220b terminal No. 3 (Yellow/White wire) and ground. If resistance is greater than 10k/ohms, go to next step. If resistance is less than 10k/ohms, repair short to ground in Yellow/White wire.
  9. Measure resistance in Pink/Orange wire between fuel pump harness connector C433 terminal No. 3 and instrument cluster harness connector terminal No. 17 (Pink/Orange wire) and also measure between harness connector C220b terminal No. 17 and ground. See Figure and Fig 1 . If resistance is 5 ohms or less, go to next step. If resistance is more than 5 ohms, repair open in appropriate wire. See WIRING DIAGRAMS .
  10. Disconnect all instrument cluster harness connectors. Inspect connectors for corrosion and pushed out pins. Connect all instrument cluster harness connectors, ensuring they are connected correctly. Operate system and verify if concern is still present. If concern is still present, replace instrument cluster. See INSTRUMENT CLUSTER  under REMOVAL & INSTALLATION. If concern is not present, system is operating correctly at this time. Clear DTCs and perform self-test.
Fig 1: Identifying Fuel Pump 4-Pin Harness Connector
G00013286Courtesy of FORD MOTOR CO.
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