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Pinpoint Test B: Incorrect Fuel Gauge Indication

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. 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 DIAGNOSTIC TOOL 
    • Key in ON position.
    • Enter the following diagnostic mode on the diagnostic tool: Instrument Cluster Active Command.
    • Select the instrument cluster active command. Trigger, monitor, and scroll the fuel gauge level at 0%, 50%, and 100%.
    • Does the fuel gauge display below E with 0%, half with 50%, and full stop with 100%? 
    • Yes  : GO to B2.
    • No  : GO to  B7.
  2. B2 CHECK THE FUEL GAUGE OPERATION 
    • Key in OFF position.
      • NOTE: The fuses must be removed to reset the fuel gauge timers. Failure to complete this step may result in erroneous test results.
    • Remove the central junction box (CJB) fuses 2 (10A), 35 (10A) and 41 (10A). Wait 1 minute and reinstall the fuses.
    • Disconnect: Fuel Tank Unit C434 (Pickup) or C4033 (Chassis Cab).
    • Connect 1 lead of the instrument gauge system tester to the fuel tank unit C434-2 (pickup) or C4033-5 (chassis cab), circuit 29 (YE/WH), harness side and the other lead to the fuel tank unit C434-4 (pickup) or C4033-8 (chassis cab), circuit 396 (BK/OG), harness side.
      Fig 1: Checking Fuel Gauge Operation
      G03924722Courtesy of FORD MOTOR CO.
    • Key in ON position.
    • On vehicles equipped with an automatic transmission, apply the brake and move the transmission shift lever from P (park) to D (drive). Wait 10 seconds, and move the transmission shift lever back to P (park). Wait 30 seconds. On vehicles equipped with a manual transmission, apply the parking brake. Wait 10 seconds, and release the parking brake. Wait 30 seconds. Do not change the tool settings or the ignition switch position until 30 seconds have elapsed.
    • Key in OFF position.
    • Set the tester to 160 ohms.
    • Key in ON position.
    • On vehicles equipped with an automatic transmission, apply the brake and move the transmission shift lever from P (park) to D (drive). Wait 10 seconds, and move the transmission shift lever back to P (park). Wait 30 seconds. On vehicles equipped with a manual transmission, apply the parking brake. Wait 10 seconds, and release the parking brake. Wait 30 seconds. Do not change the tool settings or the ignition switch position until 30 seconds have elapsed.
    • Key in OFF position.
    • Wait 30 seconds. Do not change the tool settings or the ignition switch position until 30 seconds have elapsed.
    • Set the tester to 15 ohms.
    • Key in ON position.
    • On vehicles equipped with an automatic transmission, apply the brake and move the transmission shift lever from P (park) to D (drive). Wait 10 seconds, and move the transmission shift lever back to P (park). Wait 30 seconds. On vehicles equipped with a manual transmission, apply the parking brake. Wait 10 seconds, and release the parking brake. Wait 30 seconds. Do not change the tool settings or the ignition switch position until 30 seconds have elapsed.
    • Observe the fuel gauge. The fuel gauge should read E (empty) or below.
    • Key in OFF position.
    • Wait 30 seconds. Do not change the tool settings or the ignition switch position until 30 seconds have elapsed.
    • Set the tester to 160 ohms.
    • Key in ON position.
      NOTE: Wait 1 minute for the fuel gauge to respond.

      Observe the fuel gauge. The fuel gauge should read F (full ) or above.

    • Does the fuel gauge operate correctly? 
    • Yes  : DISCONNECT the instrument gauge system tester. GO to B3.
    • No  : DISCONNECT the instrument gauge system tester. GO to  B4.
  3. B3 CHECK THE FUEL TANK 
    • Check the fuel tank for any damage or deformation.
    • Is the fuel tank OK? 
  4. B4 CHECK CIRCUITS 29 (YE/WH) AND 675 (YE/LB) FOR A SHORT TO VOLTAGE 
    • Disconnect: Instrument Cluster C220b.
    • Key in ON position.
    • For vehicles equipped with a single fuel tank, measure the voltage between the instrument cluster C220b-10, circuit 29 (YE/WH), harness side and ground.
      Fig 2: Checking Circuits 29 (YE/WH) And 675 (YE/LB) For Short To Voltage (Single Fuel Tank)
      G03924723Courtesy of FORD MOTOR CO.
    • For vehicles equipped with dual fuel tanks, measure the voltage between the instrument cluster C220b-9, circuit 675 (YE/LB), harness side and ground.
      Fig 3: Checking Circuits 29 (YE/WH) And 675 (YE/LB) For Short To Voltage (Dual Fuel Tank)
      G03924724Courtesy of FORD MOTOR CO.
    • Is any voltage present? 
    • Yes  : REPAIR the circuit in question. CLEAR the DTCs. REPEAT the self-test.
    • No  : GO to B5.
  5. B5 CHECK CIRCUITS 29 (YE/WH) AND 675 (YE/LB) FOR AN OPEN OR A SHORT TO GROUND 
    • For vehicles equipped with a single fuel tank, measure the resistance between the instrument cluster C220b-10, circuit 29 (YE/WH), harness side and the fuel tank unit C434-2 (pickup) or C4033-5 (chassis cab), circuit 29 (YE/WH), harness side; and between the instrument cluster C220b-10, circuit 29 (YE/WH), harness side and ground.
      Fig 4: Checking Circuits 29 (YE/WH) And 675 (YE/LB) For Open Or Short To Ground (Single Fuel Tank)
      G03924725Courtesy of FORD MOTOR CO.
    • Disconnect: Primary Fuel Tank Unit C3094.
    • For vehicles equipped with dual fuel tanks, measure the resistance between the instrument cluster C220b-9, circuit 675 (YE/LB), harness side and the primary fuel tank unit C3094-2, circuit 675 (YE/LB), harness side; and between the instrument cluster C220b-9, circuit 675 (YE/LB), harness side and ground.
      Fig 5: Checking Circuits 29 (YE/WH) And 675 (YE/LB) For Open Or Short To Ground (Dual Fuel Tank)
      G03924726Courtesy of FORD MOTOR CO.
    • Is the resistance less than 5 ohms between the instrument cluster and the fuel tank unit, and greater than 10,000 ohms between the instrument cluster and ground? 
    • Yes  : GO to B6.
    • No  : REPAIR the circuit in question. CLEAR the DTCs. REPEAT the self-test.
  6. B6 CHECK CIRCUIT 396 (BK/OG) FOR AN OPEN OR A SHORT TO GROUND 
    • Measure the resistance between the instrument cluster C220b-8, circuit 396 (BK/OG), harness side and the fuel tank unit C434-4 (pickup), or C4033-8 (chassis cab), circuit 396 (BK/OG), harness side; and between the instrument cluster C220b-8, circuit 396 (BK/OG), harness side and ground.
      Fig 6: Checking Circuit 396 (BK/OG) For Open Or Short To Ground
      G03924727Courtesy of FORD MOTOR CO.
    • Is the resistance less than 5 ohms between the instrument cluster and the fuel tank unit, and greater than 10,000 ohms between the instrument cluster and ground? 
    • Yes  : GO to B7.
    • No  : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test.
  7. B7 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. CLEAR the DTCs. REPEAT the self-test.
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