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Home >> Ford >> 2001 >> Windstar Base >> Repair and Diagnosis >> Electrical >> Gauges >> Instrument Panels - Analog >> System Tests >> Test D: Incorrect Fuel Gauge Indication (DTC B1201 & U1131)

Test D: Incorrect Fuel Gauge Indication (DTC B1201 & U1131)

NOTE: Fuel gauge does not change indication unless there has been at least 3 gallons of fuel added or deleted between ignition cycles.
  1. Using New Generation Star (NGS) tester, perform Rear Electronic Module (REM) and instrument cluster self-tests. If no DTCs were retrieved, go to next step. If DTCs B1201 and U1131 were retrieved, go to step  6 . If any other DTCs were retrieved, perform appropriate test in accordance with DTC retrieved. See INSTRUMENT CLUSTER MODULE DIAGNOSTIC TROUBLE CODE INDEX  and/or REAR ELECTRONIC MODULE DIAGNOSTIC TROUBLE CODE INDEX  tables under SELF-DIAGNOSTIC SYSTEM.
  2. Turn ignition switch to RUN position. Using NGS tester, select ICM FUEL GAUGE CONTROL active command. Trigger FUELLEVEL and monitor fuel gauge while adjusting FUELLEVEL active command to read 50% and 100%. Fuel gauge needle should start at empty ("E"), then half (50%), and move to full (100%). If fuel gauge needle is as specified, go to next step. If fuel gauge needle is not as specified, go to step  13 .
  3. Turn ignition switch to LOCK position. Disconnect fuel pump module 8-pin harness connector. Using Instrument Gauge System Tester (014-R1063), connect one lead to fuel pump module harness connector terminal No. 5 (Light Blue/Yellow wire). Connect second lead to fuel pump module harness connector terminal No. 8 (Light Green/Violet wire). Turn tester power switch to ON position and set tester to 15 ohms. Turn ignition switch to RUN position, wait one minute. Turn ignition switch to LOCK position. Set tester to 160 ohms. Turn ignition switch to RUN position, wait one minute. Fuel gauge should read full or above. Turn ignition switch to LOCK position. Set tester to 15 ohms. Turn ignition switch to RUN position, wait one minute. Fuel gauge should read empty or below. Turn ignition switch to LOCK position. If fuel gauge operated as specified, go to next step. If fuel gauge did not operate as specified, go to step  6 .
  4. Visually inspect fuel tank for damage or deformation. If there is no damage or deformity, go to next step. If there is damage or deformity, replace fuel tank.
  5. Inspect fuel pump assembly for damaged wiring, connectors, float and float rod or obstruction. If fuel pump or wiring is damaged, repair as necessary. If fuel pump and wiring are okay, replace fuel level sender.
  6. Turn ignition switch to LOCK position. Disconnect REM harness connectors C342 (26-pin) and C343 (20-pin). Measure resistance between ground and REM harness connector C343 terminal No. 15 (Light Green/Violet wire). See Figure . Measure resistance between ground and REM harness connector C342 terminal No. 23 (Light Blue/Yellow wire). See Figure . If any resistance is less than 10 k/ohms, go to next step. If all resistances are 10 k/ohms or more, go to step  8 .
  7. Disconnect fuel pump module 8-pin harness connector. Measure resistance between ground and REM harness connector C343 terminal No. 15 (Light Green/Violet wire). Measure resistance between ground and REM harness connector C342 terminal No. 23 (Light Blue/Yellow wire). If any resistance is less than 10 k/ohms, repair short to ground in Light Green/Violet wire or Light Blue/Yellow wire. If all resistances are 10 k/ohms or more, repair open in Light Green/Violet wire and/or Light Blue/Yellow wire.
  8. Turn ignition switch to LOCK position. Disconnect REM harness connectors C342 (26-pin) and C343 (20-pin). Disconnect fuel pump module 8-pin harness connector. Measure resistance of Light Green/Violet wire between REM harness connector terminal No. 15 and fuel pump harness connector terminal No. 8. Measure resistance of Light Blue/Yellow wire between REM harness connector C342 terminal No. 23 and fuel pump module harness connector terminal No. 5. If all resistances are less than 5 ohms, go to next step. If any resistance is 5 ohms or more, repair open in Light Green/Violet wire and/or Light Blue/Yellow wire.
  9. Measure resistance between fuel pump module terminals No. 5 and 8 (component side). If resistance is 15-160 ohms, go to next step. If resistance is not 15-160 ohms, replace fuel pump module.
  10. Measure voltage between ground and REM harness connector terminal No. 15 (Light Green/Violet wire). Measure voltage between ground and REM harness connector C342 terminal No. 23 (Light Blue/Yellow wire). If voltage does not exist at all terminals, go to next step. If voltage exists at any terminal, repair short to voltage in Light Green/Violet wire and/or Light Blue/Yellow wire.
  11. Measure voltage between ground and fuel pump module harness connector terminal No. 8 (Light Green/Violet wire). Measure voltage between ground and fuel pump module harness connector terminal No. 5 (Light Blue/Yellow wire). If voltage exists at any terminal, repair short to voltage in Light Green/Violet wire and/or Light Blue/Yellow wire. If voltage does not exist at all terminals, go to next step.
  12. Disconnect all REM harness connectors. Inspect for corrosion and pushed out pins. Connect all REM harness connectors, ensuring they seat correctly. Operate system and verify if concern is still present. If concern is still present, replace REM. Clear DTCs and perform REM self-test. If concern is not present, system is operating correctly at this time. Concern may have been caused by a loose or corroded connector.
  13. Disconnect all instrument cluster harness connectors. Inspect for corrosion and pushed out pins. Connect all instrument cluster harness connectors, ensuring they seat correctly. Operate system and verify if concern is still present. If concern is still present, replace instrument cluster. Clear DTCs and perform instrument cluster self-test. If concern is not present, system is operating correctly at this time. Concern may have been caused by a loose or corroded connector.
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