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Pinpoint Test G: The Low Fuel Warning Indicator Is Never/Always On: Testing

  1. G1 CARRY OUT THE INSTRUMENT CLUSTER WARNING LAMPS AND CHIME ACTIVE COMMAND USING THE DIAGNOSTIC TOOL 
    • Key in ON position.
    • Enter the following diagnostic mode on the scan tool: Instrument Cluster Active Command.
    • Select the instrument cluster warning lamps and chime active command. Trigger the all lamps active command on and off. Observe the low fuel warning indicator.
    • Does the low fuel warning indicator illuminate when triggered on and turn off when triggered off? 
    • Yes  : GO to G2.
    • No  : GO to  G6.
  2. G2 CHECK THE FUEL GAUGE 
    • Key in ON position.
    • Check the fuel gauge.
    • Does the fuel gauge operate correctly? 
    • Yes  : GO to G3.
    • No  : GO to PINPOINT TEST B  to continue diagnosis of the fuel gauge.
  3. G3 CHECK THE FUEL SENDER RESISTANCE READING 
    NOTE: The fuel sender resistance should be approximately 22 ohms or less when empty (E).
    • Key in OFF position.
    • Disconnect: Fuel Sender C3104.
    • Measure the resistance between the fuel sender C3104 pin 1, component side and the fuel sender C3104 pin 2, component side.
      Fig 1: Measuring Resistance Between Fuel Sender C3104 Pin 1 And Fuel Sender C3104 Pin 2
      G03992557Courtesy of FORD MOTOR CO.
    • Is the resistance within specifications? 
    • Yes  : GO to G4.
    • No  : GO to  G5.
  4. G4 CHECK THE REMOTE FUEL SENDER RESISTANCE READING 
    NOTE: The remote fuel sender resistance should be approximately 30 ohms or less when empty (E).
    • Disconnect: Remote Fuel Sender C3270.
    • Measure the resistance between the remote fuel sender C3270 pin 1, component side and the remote fuel sender C3270 pin 4, component side.
      Fig 2: Measuring Resistance Between Remote Fuel Sender C3270 Pin 1 And Remote Fuel Sender C3270 Pin 4
      G03992558Courtesy of FORD MOTOR CO.
    • Is the resistance within specifications? 
    • Yes  : CONNECT the fuel sender and the remote fuel sender. GO to  G6.
    • No  : GO to G5.
  5. G5 INSPECT THE FUEL TANK 
    • Visually inspect the fuel tank for any damage or deformation.
    • Is the fuel tank OK? 
    • Yes  : INSTALL a new fuel sender or remote fuel sender as necessary. REFER to FUEL TANK & LINES . TEST the system for normal operation.
    • No  : INSTALL a new fuel tank. REFER to FUEL TANK & LINES . TEST the system for normal operation.
  6. G6 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION 
    • Disconnect all the instrument cluster connectors.
    • Check for:
      • corrosion
      • pushed-out pins
    • Connect all the instrument cluster connectors and make sure they seat correctly.
    • Operate the system and verify the concern is still present.
    • Is the concern still present? 
    • Yes  : INSTALL a new instrument cluster. REFER to INSTRUMENT CLUSTER . TEST the system for normal operation.
    • No  : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector.