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Home >> Ford >> 2000 >> Expedition 5.4 L, RWD >> Repair and Diagnosis >> Electrical >> Gauges >> Instrument Panels - Analog - Expedition, F150/F250 Light-Duty Pickups & Navigator >> System Tests >> Test C: Fuel Gauge Inaccurate

Test C: Fuel Gauge Inaccurate

NOTE: Fuel fills of less than 6 gallons require at least 12 minutes to update fuel gauge reading.
NOTE: After repair, clear DTCs and repeat self-test.
  1. Turn ignition switch to RUN position. Using New Generation Star (NGS) tester, select instrument cluster FUEL LEVEL CONTROL active command. Trigger, observe and scroll FUELLEVEL at 0%, 54% and 100%. If fuel gauge displays below E with 0%, half with 54% and full stop with 100%, go to next step. If fuel gauge does not display below E with 0%, half with 54% and full stop with 100%, go to step  8.
  2. Turn ignition switch to OFF position. Disconnect fuel pump assembly connector located center of vehicle near fuel tank. Connect one lead of Instrument Gauge System Tester (014-R1063), or equivalent, to fuel pump assembly connector Yellow/White wire terminal and the other tester lead to fuel pump assembly connector Black/Orange wire terminal. Set tester to 15 ohms. Turn ignition switch to RUN position. Wait 5-10 minutes, fuel gauge should read below E. Turn ignition switch to OFF position. Set tester to 145 ohms. Turn ignition switch to RUN position. Wait 5-10 minutes, fuel gauge should read F or above. If fuel gauge reads as indicated, go to next step. If fuel gauge does not read as indicated, go to step  5.
  3. 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.
  4. Check fuel pump assembly in-tank mounting, float, float rod, wiring and connection for damage or obstruction. 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.
  5. Disconnect instrument panel 22-pin connector. Disconnect overhead trip computer 20-pin connector (if equipped). Turn ignition switch to RUN position. Measure voltage between instrument panel 22-pin connector terminal No. 3 (Yellow/White wire) and ground. See Figure. If voltage is present, repair short to power in Yellow/White wire. If no voltage is present, go to next step.
  6. Measure resistance of Yellow/White wire between fuel pump assembly connector and instrument panel 22-pin connector terminal No. 3. Measure resistance of Yellow/White wire between instrument panel 22-pin connector terminal No. 3 and ground. Resistance should be less than 5 ohms between instrument cluster connector and fuel sender connector, and more than 10 k/ohms between instrument cluster connector 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.
  7. Measure resistance of Pink/Orange wire between fuel pump assembly connector and instrument panel 22-pin connector terminal No. 17. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Pink/Orange wire, or Black/Orange wire. See WIRING DIAGRAMS .
  8. Disconnect all instrument cluster connectors. Inspect connectors for corrosion and pushed out pins. Connect all instrument cluster 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 repeat self-test.
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