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Test L: Incorrect Fuel Gauge Indication

WARNING: This page is about a different car, the 2002 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: For fill precautions which may affect fuel gauge indication, see TROUBLE SHOOTING .
  1. Turn ignition switch to RUN position. Connect New Generation Star (NGS) tester to Data Link Connector (DLC). DLC is located below center of instrument panel, right of steering column. Select NGS tester instrument cluster FUEL LEVEL CONTROL active command. Trigger, observe and scroll FUELLEVEL at 0%, 50% and 100%. Fuel gauge should display below empty at 0%, half at 50% and full stop at 100%. If fuel gauge displays as indicated, go to next step. If fuel gauge does not display as indicated, go to step  6.
  2. Turn ignition switch to LOCK position. Disconnect Natural Gas Vehicle Module (NGVM) harness connector C1009. NGVM is located on center radiator support behind radiator. Connect leads of Instrument Gauge System Tester (014-R1063) to NGVM harness connector C1009 terminals No. 16 (Black/Light Blue wire) and No. 38 (Yellow/White wire). Set tester to 15 ohms. Turn ignition switch to RUN position. Wait 5-10 minutes and read fuel gauge. Fuel gauge should read below empty. Turn ignition switch to LOCK position. Set tester to 160 ohms. Turn ignition switch to RUN position. Wait 5-10 minutes and read fuel gauge. Fuel gauge should read full or above. If fuel gauge does not display as indicated, disconnect tester and go to next step. If fuel gauge displays as indicated, go to step  5.
  3. Turn ignition switch to LOCK position. Disconnect instrument cluster harness connector C220b. See INSTRUMENT CLUSTER  under REMOVAL & INSTALLATION. Measure resistance in Yellow/White wire between instrument cluster harness connector C220b terminal No. 3 and NGVM harness connector C1009 terminal No. 38. See Figure and Figure . If resistance is 5 ohms or less, go to next step. If resistance is more than 5 ohms, repair open in Yellow/White wire between instrument cluster and NGVM. See WIRING DIAGRAMS .
  4. Measure voltage at NGVM harness connector C1009 between terminals No. 38 (Yellow/White wire) and No. 40 (Black/Yellow wire). If any voltage is present, repair short to voltage in Yellow/White wire. If there is no voltage present, repair short to ground in Yellow/White wire between instrument cluster and NGVM. See WIRING DIAGRAMS .
  5. Disconnect NGVM harness connector C1009. NGVM is located on center radiator support behind radiator. Inspect for pushed out terminals and corrosion. Reconnect NGVM harness connector, ensuring it is connected correctly. Operate system and verify if concern still exists. If concern still exists, replace NGVM. See NATURAL GAS VEHICLE MODULE  under REMOVAL & INSTALLATION. If concern does not exist, system is operating correctly at this time. Clear DTCs and repeat self-test.
  6. Disconnect both instrument cluster harness connectors. Inspect for pushed out terminals and corrosion. Reconnect instrument cluster harness connectors, ensuring they are connected correctly. Operate system and verify if concern still exists. If concern still exists, replace instrument cluster. See INSTRUMENT CLUSTER  under REMOVAL & INSTALLATION. If concern does not exist, system is operating correctly at this time. Clear DTCs and repeat self-test.
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