Test A: Fuel Gauge Inaccurate
WARNING: This page is about a different car, the 2002 Ford RV Cutaway, 2002 Ford F450 Super Duty, 2002 Ford Econoline, 2002 Ford E450 Super Duty, and 2002 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:
Anti-slosh circuitry will cause fuel gauge to take about 20 minutes to go from empty to full if fueled with ignition switch in ON position.
NOTE:
Fuel gauge sending unit Black 4-pin harness connector (Cutaway and RV Cutaway) is located below left center of vehicle on in-transit fuel pump module. Fuel gauge sending unit Black 4-pin harness connector (Except Cutaway and RV Cutaway) is located below vehicle on fuel pump module. For purposes of this test, both connectors will be referred to as fuel sending unit Black 4-pin harness connector.
- Turn ignition switch to LOCK position. Disconnect fuel gauge sending unit Black 4-pin harness connector. Using Instrument Gauge System Tester (014-R-1063), connect one tester lead to fuel gauge sending unit Black 4-pin harness connector terminal No. 2 (Yellow/White wire). See Fig 1. Connect second lead to ground. Set instrument gauge system tester to 160 ohms. Turn ignition switch to ON position. Turn instrument gauge system tester on. Wait one minute. Read fuel gauge. Fuel gauge should read "F" or above. Turn ignition switch to LOCK position. Set instrument gauge system tester to 15 ohms. Turn ignition switch to ON position. Wait one minute. Read fuel gauge. Fuel gauge should read "E" or below. If fuel gauge reads as specified, turn ignition switch to LOCK position. Disconnect instrument gauge system tester and go to next step. If fuel gauge does not read as specified, turn ignition switch to LOCK position. Disconnect tester and go to step 4.
- Visually inspect fuel tank for damage. If fuel tank is okay, go to next step. If fuel tank is damaged, repair or replace as necessary. Retest system operation.
- Visually inspect fuel pump assembly for damage or corroded connections and harness. Inspect float and float rod for damage or obstruction. If fuel pump assembly and harness are okay, replace fuel gauge sending unit. See FUEL GAUGE SENDING UNIT under REMOVAL & INSTALLATION. If fuel pump assembly and/or harness is damaged, replace or repair as necessary. Retest system operation.
- Measure resistance between ground and fuel gauge sending unit Black 4-pin harness connector terminal No. 3 (Black/Yellow wire). If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Black/Yellow wire. See WIRING DIAGRAMS . Retest system operation.
- Turn ignition switch to LOCK position. Disconnect instrument cluster White 16-pin harness connector C220a. Measure resistance of Yellow/White wire between fuel gauge sending unit Black 4-pin harness connector terminal No. 2 and instrument cluster White 16-pin harness connector C220a terminal No. 10. See Fig 1 and Fig 2 . Resistance should be 5 ohms or less. Measure resistance between ground and instrument cluster White 16-pin harness connector C220a terminal No. 10 (Yellow/White wire). Resistance should be more than 10 k/ohms. If resistances are as specified, replace instrument cluster. See INSTRUMENT CLUSTER under REMOVAL & INSTALLATION. Retest system operation. If resistances are not as specified, repair open or short to ground in Yellow/White wire. See WIRING DIAGRAMS . Retest system operation.