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Pinpoint Test B: Incorrect Fuel Gauge Indication: Testing

WARNING: This page is about a different car, the 2005 Mercury Montego, 2005 Ford Freestyle, and 2005 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.
  1. B1 CARRY OUT THE INSTRUMENT CLUSTER FUEL GAUGE ACTIVE COMMAND USING THE SCAN TOOL 
    • Key in ON position.
    • Enter the following diagnostic mode on the scan tool: Instrument Cluster Active Command.
    • Trigger the instrument cluster on-demand self-test while observing the fuel gauge.
    • Does the fuel gauge sweep from E (empty) to F (full)? 
    • Yes  : GO to B2.
    • No  : GO to  B18.
  2. B2 CHECK FOR INSTRUMENT CLUSTER DTCs 
    • Key in OFF position.
    • Check for recorded instrument cluster DTCs from the continuous and on-demand self-tests.
    • Are any DTCs recorded? 
    • Yes  : For DTC B1204 or B2628, GO to B3.

      For DTC B1202, GO to  B5.

      For DTC B2627, GO to  B10.

      For DTC B2879, GO to  B15.

    • No  : GO to  B15.
  3. B3 CHECK THE FUEL SENDER FOR A SHORT TO GROUND 
    NOTE: The fuel pump module is also called the fuel sender.
    NOTE: The fuel level sensor is also called the remote fuel sender.
    • Disconnect: Fuel Pump Module C3104 (DTC B1204) or Fuel Level Sensor C3270 (DTC B2628).
    • Key in ON position.
    • Repeat the instrument cluster on-demand self-test.
    • Is DTC B1204 or B2628 retrieved? 
    • Yes  : GO to B4.
    • No  : INSTALL a new fuel sender in question. REFER to FUEL TANK & LINES . CLEAR the DTCs. REPEAT the self-test.
  4. B4 CHECK CIRCUIT 29 (YE/WH) (DTC B1204) OR CIRCUIT 1356 (LG/VT) (DTC B2628) FOR A SHORT TO GROUND 
    • Key in OFF position.
    • Disconnect: Instrument Cluster C220.
    • Measure the resistance between the instrument cluster C220-14 (DTC B1204), circuit 29 (YE/WH) harness side and ground; or between the instrument cluster C220-16 (DTC B2628), circuit 1356 (LG/VT) harness side and ground.
      Fig 1: Measuring Resistance Between Instrument Cluster C220-14 And Ground
      G03992539Courtesy of FORD MOTOR CO.
    • Is the resistance greater than 10,000 ohms? 
    • Yes  : GO to  B18.
    • No  : REPAIR the circuit in question. CLEAR the DTCs. REPEAT the self-test.
  5. B5 CHECK THE FUEL PUMP MODULE CIRCUITRY FOR A SHORT TO VOLTAGE 
    • Disconnect: Instrument Cluster C220.
    • Key in ON position.
    • Measure the voltage between the instrument cluster C220-14, circuit 29 (YE/WH), harness side and ground; and between the instrument cluster C220-15, circuit 1843, (BK/OG), harness side and ground.
      Fig 2: Measuring Voltage Between Instrument Cluster C220-14 And Ground
      G03992540Courtesy of FORD MOTOR CO.
    • Is any voltage present? 
    • Yes  : GO to B6.
    • No  : GO to  B7.
  6. B6 CHECK THE FUEL PUMP MODULE FOR A SHORT TO VOLTAGE 
    • Key in OFF position.
    • Disconnect: Fuel Pump Module C3104.
    • Key in ON position.
    • Measure the voltage between the instrument cluster C220-14, circuit 29 (YE/WH), harness side and ground; and between the instrument cluster C220-15, circuit 1843, (BK/OG), harness side and ground.
      Fig 3: Measuring Voltage Between Instrument Cluster C220-14 And Ground
      G03992540Courtesy of FORD MOTOR CO.
    • Is any voltage present? 
    • Yes  : REPAIR the circuit in question. CLEAR the DTCs. REPEAT the self-test.
    • No  : INSTALL a new fuel pump module. REFER to FUEL TANK & LINES . CLEAR the DTCs. REPEAT the self-test.
  7. B7 CHECK THE FUEL PUMP MODULE CIRCUITRY FOR AN OPEN 
    • Key in OFF position.
    • Disconnect: Fuel Pump Module C3104.
    • Connect a fused (5A) jumper wire between the fuel pump module C3104-2, circuit 29 (YE/WH), harness side and the fuel pump module C3104-1, circuit 1843 (BK/OG), harness side.
      Fig 4: Connecting Fused Jumper Wire Between Fuel Pump Module And Fuel Pump Module
      G03992542Courtesy of FORD MOTOR CO.
    • Measure the resistance between the instrument cluster C220-14, circuit 29 (YE/WH), harness side and the instrument cluster C220-15, circuit 1843 (BK/OG), harness side.
      Fig 5: Measuring Resistance Between Instrument Cluster C220-14 And Instrument Cluster C220-15
      G03992543Courtesy of FORD MOTOR CO.
    • Is the resistance less than 5 ohms? 
    • Yes  : REMOVE the jumper wire. GO to B8.
    • No  : REMOVE the jumper wire. GO to  B9.
  8. B8 CHECK THE FUEL PUMP MODULE FOR AN OPEN 
    NOTE: The fuel sender resistance varies from 15 + 2 ohms when empty (E) to 160 + 4 ohms when full (F).
    • Measure the resistance between the fuel pump module C3104 pin 1, component side and the fuel pump module C3104 pin 2, component side.
      Fig 6: Measuring Resistance Between Fuel Pump Module C3104 Pin 1 And Fuel Pump Module C3104 Pin 2
      G03992544Courtesy of FORD MOTOR CO.
    • Is the resistance between 15 and 160 ohms? 
    • Yes  : GO to  B18.
    • No  : INSTALL a new fuel pump module. REFER to FUEL TANK & LINES . CLEAR the DTCs. REPEAT the self-test.
  9. B9 CHECK CIRCUIT 29 (YE/WH) FOR AN OPEN 
    • Measure the resistance between the instrument cluster C220-14, circuit 29 (YE/WH), harness side and the fuel pump module C3104-2, circuit 29 (YE/WH), harness side.
      Fig 7: Measuring Resistance Between Instrument Cluster C220-14 And Fuel Pump Module C3104-2
      G03992545Courtesy of FORD MOTOR CO.
    • Is the resistance less than 5 ohms? 
    • Yes  : REPAIR circuit 1843 (BK/OG) for an open. CLEAR the DTCs. REPEAT the self-test.
    • No  : REPAIR circuit 29 (YE/WH). CLEAR the DTCs. REPEAT the self-test.
  10. B10 CHECK THE FUEL LEVEL SENSOR CIRCUITRY FOR A SHORT TO VOLTAGE 
    • Disconnect: Instrument Cluster C220.
    • Key in ON position.
    • Measure the voltage between the instrument cluster C220-16, circuit 1356 (LG/VT), harness side and ground; and between the instrument cluster C220-17, circuit 1357 (LB/YE), harness side and ground.
      Fig 8: Measuring Voltage Between Instrument Cluster C220-16 And Ground
      G03992546Courtesy of FORD MOTOR CO.
    • Is any voltage present? 
    • Yes  : GO to B11.
    • No  : GO to  B12.
  11. B11 CHECK CIRCUIT 1356 (LG/VT) FOR A SHORT TO VOLTAGE 
    • Key in OFF position.
    • Disconnect: Fuel Level Sensor S3270.
    • Measure the voltage between the instrument cluster C220-16, circuit 1356 (LG/VT), harness side and ground.
      Fig 9: Measuring Voltage Between Instrument Cluster C220-16 And Ground
      G03992547Courtesy of FORD MOTOR CO.
    • Is any voltage present? 
    • Yes  : REPAIR circuit 1356 (LG/VT). CLEAR the DTCs. REPEAT the self-test.
    • No  : REPAIR circuit 1357 (LB/YE) for a short to voltage. CLEAR the DTCs. REPEAT the self-test.
  12. B12 CHECK THE FUEL LEVEL SENSOR FOR AN OPEN 
    NOTE: The fuel sender resistance varies from 15 + 2 ohms when empty (E) to 160 + 4 ohms when full (F).
    • Key in OFF position.
    • Disconnect: Fuel Level Sensor C3270.
    • Measure the resistance between the fuel level sensor C3270 pin 1, component side and the fuel level sensor C3270 pin 4, component side.
      Fig 10: Measuring Resistance Between Fuel Level Sensor C3270 Pin 1 And Fuel Level Sensor C3270 Pin 4
      G03992548Courtesy of FORD MOTOR CO.
    • Is the resistance between 15 and 160 ohms? 
    • Yes  : GO to B13.
    • No  : INSTALL a new fuel level sensor. REFER to FUEL TANK & LINES . CLEAR the DTCs. REPEAT the self-test.
  13. B13 CHECK THE FUEL LEVEL SENSOR CIRCUITRY FOR AN OPEN 
    • Connect a fused (5A) jumper wire between the fuel level sensor C3270-4, circuit 1356 (LG/VT), harness side and the fuel level sensor C3270-1, circuit 1357 (LB/YE), harness side.
      Fig 11: Connecting Fused Jumper Wire Between Fuel Level Sensor C3270-4 And Fuel Level Sensor C3270-1
      G03992549Courtesy of FORD MOTOR CO.
    • Measure the resistance between the instrument cluster C220-16, circuit 1356 (LG/VT), harness side and the instrument cluster C220-17, circuit 1357 (LB/YE), harness side.
      Fig 12: Measuring Resistance Between Instrument Cluster C220-16 And Instrument Cluster C220-17
      G03992550Courtesy of FORD MOTOR CO.
    • Is the resistance less than 5 ohms? 
    • Yes  : REMOVE the jumper wire. GO to  B18.
    • No  : REMOVE the jumper wire. GO to B14.
  14. B14 CHECK CIRCUIT 1356 (LG/VT) FOR AN OPEN 
    • Measure the resistance between the instrument cluster C220-16, circuit 1356 (LG/VT), harness side and the fuel sender C3270-4, circuit 1356 (LG/VT), harness side.
      Fig 13: Measuring Resistance Between Instrument Cluster C220-16 And Fuel Sender C3270-4
      G03992551Courtesy of FORD MOTOR CO.
    • Is the resistance less than 5 ohms? 
    • Yes  : REPAIR circuit 1357 (LB/YE) for an open. CLEAR the DTCs. REPEAT the self-test.
    • No  : REPAIR circuit 1356 (LG/VT). CLEAR the DTCs. REPEAT the self-test.
  15. B15 INSPECT THE FUEL TANK 
    • Visually inspect the fuel tank for any damage or deformation.
    • Is the fuel tank OK? 
    • Yes  : GO to B16.
    • No  : INSTALL a new fuel tank. REFER to FUEL TANK & LINES . CLEAR the DTCs. REPEAT the self test.
  16. B16 INSPECT THE FUEL TANK TRANSFER TUBE CONNECTIONS 
    • Remove the fuel pump module and the fuel level sensor. Refer to FUEL TANK & LINES .
    • Inspect the fuel tank transfer tube, connections, the fuel pump module and the fuel level sensor for any damage or deformation.
    • Are the fuel tank transfer tube, connections, the fuel pump module and the fuel level sensor OK? 
    • Yes  : GO to B17.
    • No  : INSTALL a new fuel tank transfer tube, fuel pump module or fuel level sensor as necessary. REFER to FUEL TANK & LINES . CLEAR the DTCs. REPEAT the self test.
  17. B17 CHECK THE FUEL PUMP MODULE AND THE FUEL LEVEL SENSOR FOR CORRECT OPERATION 
    NOTE: The resistance varies from 15 +/- 2 ohms when empty (E) to 160 +/- 4 ohms when full (F).
    • For the fuel pump module, measure the resistance between the fuel pump module C3104 pin 1, component side and the fuel pump module C3104 pin 2, component side while slowly moving the float arm from the bottom to the top of travel.
      Fig 14: Measuring Resistance Between Fuel Pump Module C3104 Pin 1 And Fuel Pump Module C3104 Pin 2
      G03992544Courtesy of FORD MOTOR CO.
    • For the fuel level sensor, measure the resistance between the fuel level sensor C3270 pin 1, component side and the fuel level sensor C3270 pin 4, component side while slowly moving the float arm from the bottom to the top of travel.
      Fig 15: Measuring Resistance Between Fuel Level Sensor C3270 Pin 1 And Fuel Level Sensor C3270 Pin 4
      G03992548Courtesy of FORD MOTOR CO.
    • Does the resistance start at approximately 15 ohms with the float at the bottom of travel and slowly increase to approximately 160 ohms at the top of travel? 
    • Yes  : INSTALL a new fuel tank transfer tube. REFER to FUEL TANK & LINES . CLEAR the DTCs. REPEAT the self test.
    • No  : INSTALL a new fuel pump module or fuel level sensor as necessary. REFER to FUEL TANK & LINES . CLEAR the DTCs. REPEAT the self-test.
  18. B18 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION 
    • Disconnect the instrument cluster connector.
    • Check for:
      • corrosion
      • pushed-out pins
    • Connect the instrument cluster connector and make sure it seats 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. CLEAR the DTCs. REPEAT the self-test.
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