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Pinpoint Test I: The Check Fuel Cap Warning Indicator Is Never On

WARNING: This page is about a different car, the 2004 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
  1. I1 CHECK THE CHECK FUEL CAP WARNING INDICATOR OPERATION 
    • Key in ON position.
    • Observe the check fuel cap warning indicator prove-out.
    • Does the check fuel cap warning indicator prove-out correctly? 
    1. Yes  : System is operating correctly at this time.
    2. No  : If the indicator is always on, GO to I2.

      If the indicator is never on, GO to  I4.

  2. I2 CHECK THE PCM 
    • Key in OFF position.
    • Disconnect: PCM C175.
    • Key in ON position.
    • Observe the check fuel cap warning indicator.
    • Does the check fuel cap warning indicator continue to illuminate? 
    1. Yes  : GO to I3.
    2. No  : GO to  I7.
  3. I3 CHECK CIRCUIT 1017 (BK/WH) FOR A SHORT TO GROUND 
    • Key in OFF position.
    • Disconnect: Instrument Cluster C220a.
    • Measure the resistance between the instrument cluster C220a pin 19, circuit 1017 (BK/WH), harness side and ground.
      Fig 1: Checking Circuit 1017 (BK/WH) For Short To Ground
      G03277049Courtesy of FORD MOTOR CO.
    • Is the resistance greater than 10,000 ohms? 
    1. Yes  : GO to I4.
    2. No  : REPAIR the circuit. TEST the system for normal operation.
  4. I4 CHECK CIRCUIT 1017 (BK/WH) 
    • Disconnect: PCM C175.
      • NOTE: If the fuse fails, repair the circuit for a short to power.
    • Connect a fused (5A) jumper wire between the PCM C175 pin 82, circuit 1017 (BK/WH) and ground.
      • Fig 2: Checking Circuit 1017 (BK/WH)
      G03277050Courtesy of FORD MOTOR CO.
    • Key in ON position.
    • Is the check fuel cap warning indicator still illuminated? 
    1. Yes  : GO to  I7.
    2. No  : GO to I5.
  5. I5 CHECK CIRCUIT 1017 (BK/WH) FOR AN OPEN 
    • Key in OFF position.
    • Disconnect: Instrument Cluster C220a.
    • Disconnect: PCM C175.
    • Measure the resistance between the instrument cluster C220a pin 19, circuit 1017 (BK/WH), harness side and the PCM C175 pin 82, circuit 1017 (BK/WH), harness side.
      Fig 3: Checking Circuit 1017 (BK/WH) For An Open
      G03277051Courtesy of FORD MOTOR CO.
    • Is the resistance less than 5 ohms? 
    1. Yes  : GO to I6.
    2. No  : REPAIR the system for normal operation.
  6. I6 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION 
    • Disconnect all instrument cluster connectors.
    • Check for:
    • Corrosion
    • Pushed-out pins
    • Connect all instrument cluster connectors and make sure they seat correctly.
    • Operate the system and verify the concern is still present.
    • Is the concern still present? 
    1. Yes  : INSTALL a new instrument cluster. REFER to INSTRUMENT CLUSTER . CLEAR the DTCs. REPEAT the instrument cluster self-test.
    2. No  : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test.
  7. I7 CHECK FOR CORRECT PCM OPERATION 
    • Disconnect the PCM connector.
    • Check for:
    • Corrosion
    • Pushed-out pins
    • Connect the PCM connector and make sure it seats correctly.
    • Operate the system and verify the concern is still present.
    • Is the concern still present? 
    1. Yes  : INSTALL a new PCM. REFER to ELECTRONIC ENGINE CONTROLS . CLEAR the DTCs. REPEAT the PCM self-test.
    2. No  : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test.
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