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Test B: Fuel Level Always Reads Empty

  1. Check fuel gauge. See FUEL GAUGE  under COMPONENT TESTS. Is the fuel gauge okay? If yes, go to next step. If no, replace fuel gauge. See FUEL GAUGE  under REMOVAL & INSTALLATION.
  2. Check signal from fuel level sensor. See FUEL LEVEL SENSOR  under COMPONENT TESTS. Is the fuel level sensor okay? If yes, go to next step. If no, replace the fuel level sensor. See FUEL LEVEL SENSOR (SENDING UNIT)  under REMOVAL & INSTALLATION.
  3. Check wire between instrument cluster and fuel pump assembly. Turn key OFF. Disconnect the instrument cluster connector C270 and the fuel pump assembly connector. Measure the resistance of the Blue/Red wire between the instrument cluster connector C270 and ground. Is the resistance greater than 10,000 ohms? If yes, go to next step. If no, service Blue/Red wire for short. See WIRING DIAGRAMS  .
    4. NOTE: Fuel indicator module is also known as the anti-slosh module.
    Fig 1: Identifying Fuel Indicator Module Terminals
    G00101247Courtesy of FORD MOTOR CO.
  4. Check power supply to fuel indicator module. Turn key OFF. Reconnect the instrument cluster connector C270. Remove the fuel indicator module from the back of the instrument cluster. Turn key ON. Measure the voltage on Pin No. 2 of the fuel indicator module connector on the back of the instrument cluster. See Fig 1 . Is the voltage greater than 10 volts? If yes, go to next step. If no, see step  4 of TEST A: INTEGRATED CIRCUIT DISPLAY(S) INOPERATIVE OR ERRATIC  .
  5. Check fuel indicator module to ground. Turn key OFF. Reconnect the instrument cluster connector C270. Remove the fuel indicator module from the back of the instrument cluster. Measure the resistance between Pin No. 3 of the fuel indicator module connector and ground. Is the resistance less than 5 ohms? If yes, go to next step. If no, see step  4 of TEST A: INTEGRATED CIRCUIT DISPLAY(S) INOPERATIVE OR ERRATIC  .
  6. Check fuel indicator module. Turn key OFF. Reconnect the fuel indicator module connector. Disconnect all of the instrument cluster connectors. Using a jumper, connect Pin No. 2 of the fuel indicator module to the battery positive terminal. Using a jumper, connect Pin No. 3 of the fuel indicator module to the battery negative cable. Connect Rotunda Instrument Gauge System Tester (021-00055) or equivalent between Pin No. 5 of the fuel indicator module and the battery negative terminal. Measure the voltage on Pin No. 4 of the fuel indicator module under specified conditions. See FUEL INDICATOR MODULE RESISTANCE  table. Are the voltage readings (approximately) as specified? If yes, replace the instrument cluster printed circuit. See INSTRUMENT CLUSTER PRINTED CIRCUIT  under REMOVAL & INSTALLATION. If no, replace fuel indicator module. See FUEL INDICATOR MODULE  under REMOVAL & INSTALLATION.
FUEL INDICATOR MODULE RESISTANCE

Fuel Gauge Resistance (Ohms) Voltage (Volts)
Full 160 5.55
3/4 130 5.20
1/2 95 4.62
1/4 63 3.74
Empty 23 2.14
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