Test C: Fuel Sender Open, Shorted Or Inaccurate
WARNING: This page is about a different car, the 2002 Lincoln Navigator and 2002 Ford Expedition. 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.
- 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 8.
- Turn ignition switch to LOCK position. Disconnect fuel pump assembly Black 8-pin harness connector C415. Connector C415 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 C415 terminal No. 5 (Yellow/White wire) and the other tester lead to terminal No. 8 (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 F or more. If fuel gauge reads as indicated, go to next step. If fuel gauge does not read as indicated, go to step 5.
- 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 in REMOVAL, OVERHAUL & INSTALLATION article in ENGINE PERFORMANCE.
- Check fuel pump in-tank assembly mounting, float, float rod, wiring and connections for damage or obstruction. If fuel pump and wiring are okay, replace fuel sender. See FUEL PUMP in REMOVAL, OVERHAUL & INSTALLATION article in ENGINE PERFORMANCE. If fuel pump assembly and/or wiring is damaged, repair or replace fuel pump as necessary. See FUEL PUMP in REMOVAL, OVERHAUL & INSTALLATION article in ENGINE PERFORMANCE.
- Remove instrument cluster. See INSTRUMENT CLUSTER in REMOVAL & INSTALLATION. Disconnect instrument cluster 22-pin harness connector C237. Disconnect overhead trip computer 20-pin harness connector C928 (if equipped). Turn ignition switch to RUN position. Measure voltage between ground and instrument cluster harness connector C237 terminal No. 3 (Yellow/White wire). See Figure. If battery voltage does not exist, go to next step. If battery voltage exists, repair short to power in Yellow/White wire between instrument cluster and overhead trip computer. See WIRING DIAGRAMS .
- Measure resistance in Yellow/White wire between terminal No. 5 at fuel pump assembly harness connector C415 and terminal No. 3 at instrument cluster harness connector C237. See Figure and Fig 1 . Measure resistance between ground and instrument cluster 22-pin harness connector C237 terminal No. 3 (Yellow/White wire). Resistance should be 5 ohms or less between instrument cluster harness connector C237 and fuel sender harness connector C415, and more than 10 k/ohms between instrument cluster harness connector C237 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 .
- Measure resistance in Black/Orange wire between fuel pump harness connector C415 terminal No. 8 and instrument cluster harness connector terminal No. 17 (Pink/Orange wire). 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 ground wire. See WIRING DIAGRAMS .
- 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.