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Home >> Ford Truck >> 2012 >> Explorer FWD L4-2.0L Turbo >> Repair and Diagnosis >> Instrument Panel, Gauges and Warning Indicators >> Testing and Inspection >> Pinpoint Tests >> Instrumentation, Message Center, and Warning Chimes >> Diagnostic Routine B

Diagnostic Routine B




Diagnostic Routine B

Diagnostic Overview

Incorrect Fuel Gauge Indication

Refer to Wiring Diagram Set 60 for schematic and connector information Electrical Diagrams.

Normal Operation and Fault Conditions

NOTE: A slight fluctuation in the fuel gauge needle is normal on the optional (video display) IPC (Instrument Panel Cluster). Do not fault the IPC (Instrument Panel Cluster) for this concern.

The fuel gauge uses inputs from the fuel pump assembly and the fuel level sensor to provide the fuel level indication. For information on the fuel gauge and fuel level sender, REFER to Fuel Gauge and REFER to Fuel Level Sender .

IPC (Instrument Panel Cluster) DTC Fault Trigger Conditions





PCM (Powertrain Control Module) DTC Fault Trigger Conditions






Visual Inspection and Diagnostic Pre-checks

Inspect the fuel tank for signs of damage that can affect the float operation inside the tank. Inspect the fuel gauge needle on the base IPC (Instrument Panel Cluster) or the fuel gauge display area of the LH (Left Hand) display screen on the optional IPC (Instrument Panel Cluster).

Special Tool(s)






Pinpoint Test

1. CARRY OUT THE IPC (Instrument Panel Cluster) SELF-TEST

1. Using a scan tool, perform the IPC (Instrument Panel Cluster) self-test.

Are any DTCs (Diagnostic Trouble Codes) recorded?








2. CHECK THE FUEL INPUT FOR A SHORT TO GROUND

1. Disconnect: Fuel Pump Assembly (DTC (Diagnostic Trouble Code) P0460:11).

2. Disconnect: Fuel Level Sensor (DTC (Diagnostic Trouble Code) P1346:11).

3. Ignition ON.

4. Wait one minute.

5. NOTE: DTC (Diagnostic Trouble Code) P0460:11 or P1346:11 can also be present.
Using a scan tool, repeat the IPC (Instrument Panel Cluster) on-demand self-test.

Is DTC (Diagnostic Trouble Code) P0460:13 or P1346:13 retrieved?








3. CHECK THE FUEL PUMP ASSEMBLY AND FUEL LEVEL SENSOR SIGNAL CIRCUIT FOR A SHORT TO GROUND

1. Ignition OFF.

2. Disconnect: IPC (Instrument Panel Cluster).

3. Measure:





Is the resistance greater than 10,000 ohms?








4. CHECK THE FUEL PUMP ASSEMBLY SIGNAL AND RETURN CIRCUITS FOR A SHORT TOGETHER

1. Measure:





Is the resistance greater than 10,000 ohms?








5. CHECK THE FUEL LEVEL SENSOR SIGNAL AND RETURN CIRCUITS FOR A SHORT TOGETHER

1. Measure:





Is the resistance greater than 10,000 ohms?








6. CHECK THE FUEL PUMP ASSEMBLY OR FUEL LEVEL SENSOR FOR AN OPEN

1. Ignition OFF.

2. Disconnect: Fuel Pump Assembly (DTC (Diagnostic Trouble Code) P0460:13).

3. Disconnect: Fuel Level Sensor (DTC (Diagnostic Trouble Code) P1346:13).

4. For DTC (Diagnostic Trouble Code) P0460:13, connect a fused jumper wire:





5. For DTC (Diagnostic Trouble Code) P1346:13, connect a fused jumper wire:





6. Ignition ON.

7. Wait one minute.

8. NOTE: DTC (Diagnostic Trouble Code) P0460:13 or P1346:13 can also be present when carrying out this step and should be ignored at this time.
Using a scan tool, repeat the IPC (Instrument Panel Cluster) self-test.

9. Retrieve the IPC (Instrument Panel Cluster) continuous DTCs (Diagnostic Trouble Codes).

Is DTC (Diagnostic Trouble Code) P0460:11 or P1346:11 retrieved?








7. CHECK THE FUEL LEVEL SIGNAL CIRCUIT FOR A SHORT TO VOLTAGE

1. Ignition OFF.

2. Disconnect: IPC (Instrument Panel Cluster).

3. Ignition ON.

4. Measure:





Is any voltage present?








8. CHECK THE FUEL LEVEL SIGNAL CIRCUIT FOR AN OPEN

1. Ignition OFF.

2. Measure:





Is the resistance less than 3 ohms?








9. CHECK THE FUEL LEVEL RETURN CIRCUIT FOR AN OPEN

1. Measure:





Is the resistance less than 3 ohms?








10. CHECK THE FUEL LEVEL SENSOR SIGNAL CIRCUIT FOR A SHORT TO VOLTAGE

1. Disconnect: IPC (Instrument Panel Cluster).

2. Ignition ON.

3. Measure:





Is any voltage present?








11. CHECK THE FUEL LEVEL SENSOR SIGNAL CIRCUIT FOR AN OPEN

1. Measure:





Is the resistance less than 3 ohms?








12. CHECK THE FUEL LEVEL SENSOR RETURN CIRCUIT FOR AN OPEN

1. Measure:





Is the resistance less than 3 ohms?








13. CARRY OUT THE IPC (Instrument Panel Cluster) FUEL GAUGE ACTIVE COMMAND USING THE SCAN TOOL

1. Ignition ON.

2. Using a scan tool, view the IPC (Instrument Panel Cluster) PIDs (Parameter Identifications).

3. Select and command the fuel gauge PID (Parameter Identification) (FuelLevel) from 0% to 25%, 50%, 75% and 100% while observing the fuel gauge.

Does the fuel gauge begin at (E) empty, move to approximately 1/4, 1/2, 3/4 and F (full)?








14. CHECK THE FUEL PUMP ASSEMBLY INPUT TO THE IPC

1. Disconnect: Fuel Pump Assembly.

2. Ignition OFF.

3. NOTE: Since the IPC (Instrument Panel Cluster) can be in anti-slosh mode, the self-test and tester values may not match the fuel gauge readings. Disregard the actual gauge indication during this test step.
Connect the universal gauge tester OTC3385 :





4. Ignition ON.

5. Using a scan tool, view the IPC (Instrument Panel Cluster) PIDs (Parameter Identifications).

6. NOTE: It is extremely important to confirm the universal gauge tester settings with an ohmmeter to make sure the universal gauge tester is in the correct position. Failure to follow this check can result in inaccurate test results.
Select and monitor the IPC (Instrument Panel Cluster) fuel level (FUELLVL1) PID (Parameter Identification) with the instrument gauge system tester set at 180 ohms, 90 ohms, 55 ohms, 30 ohms and 10 ohms.

Does the PID (Parameter Identification) begin at approximately 3, move to 70, 127, 185 then 251?








15. CHECK THE FUEL PUMP ASSEMBLY SIGNAL AND RETURN CIRCUITS FOR A HIGH RESISTANCE

1. Ignition OFF.

2. Disconnect: IPC (Instrument Panel Cluster).

3. Connect a fused jumper wire:





4. Measure:





Is the resistance less than 3 ohms?








16. CHECK THE FUEL LEVEL SENSOR INPUT TO THE IPC (Instrument Panel Cluster)

1. Ignition OFF.

2. Disconnect: Fuel Level Sensor.

3. NOTE: Since the IPC (Instrument Panel Cluster) can be in anti-slosh mode, the self-test and tester values may not match the fuel gauge readings. Disregard the actual gauge indication during this test step.
Connect the universal gauge tester OTC3385 :





4. Ignition ON.

5. Using a scan tool, view the IPC (Instrument Panel Cluster) PIDs (Parameter Identifications).

6. NOTE: It is extremely important to confirm the universal gauge tester settings with an ohmmeter to make sure the universal gauge tester is in the correct position. Failure to follow this check can result in inaccurate test results.
Select and monitor the IPC (Instrument Panel Cluster) fuel level (FUELLVL2) PID (Parameter Identification) with the instrument gauge system tester set at 180 ohms, 90 ohms, 55 ohms, 30 ohms and 10 ohms.

Does the PID (Parameter Identification) begin at approximately 3 move to 70, 127, 185 then 251?








17. CHECK THE FUEL LEVEL SENSOR SIGNAL AND RETURN CIRCUITS FOR A HIGH RESISTANCE

1. Ignition OFF.

2. Disconnect: IPC (Instrument Panel Cluster).

3. Connect a fused jumper wire:





4. Measure:





Is the resistance less than 3 ohms?








18. INSPECT THE FUEL TANK

1. Visually inspect the fuel tank for any damage or deformation.

Is the fuel tank OK?








19. INSPECT THE FUEL TANK TRANSFER TUBE CONNECTIONS

1. Remove the fuel pump assembly and the fuel level sensor. REFER to Fuel Pump Assembly and REFER to Fuel Level Sensor .

2. Inspect the fuel tank transfer tube, connections, the fuel pump assembly and the fuel level sensor for any damage or deformation.

Are the fuel tank transfer tube, connections, the fuel pump assembly and the fuel level sensor OK?








20. CHECK THE FUEL PUMP ASSEMBLY AND FUEL LEVEL SENSOR

1. Inspect the fuel pump assembly and fuel level sensor connector.

2. Repair:

- corrosion (install new connector or terminals- clean module pins)
- damaged pins - install new terminals/pins
- pushed-out pins - install new pins as necessary

3. Reconnect the fuel pump assembly and fuel level sensor connector. Make sure they seat and latch correctly.

4. Operate the system and determine if the concern is still present.

Is the concern still present?








21. CHECK THE FUEL LEVEL SENDER

1. Remove the fuel pump assembly. REFER to Fuel Pump Assembly .

2. Disconnect the fuel level sender input wire from the fuel pump assembly.

3. NOTE: The fuel level sender resistance measures between 10 ohms± 2 ohms at the upper stop position and 180 ohms± 4 ohms at the lower stop position.
Measure the resistance while slowly moving the float arm between the lower and upper stop position:





Does the resistance slowly decrease from approximately 180 ohms to 10 ohms?








22. CHECK FOR CORRECT IPC (Instrument Panel Cluster) OPERATION

1. Disconnect and inspect the IPC (Instrument Panel Cluster) connector.

2. Repair:

- corrosion (install new connector or terminals- clean module pins)
- damaged pins - install new terminals/pins
- pushed-out pins - install new pins as necessary

3. Reconnect the IPC (Instrument Panel Cluster) connector. Make sure it seats and latches correctly.

4. Operate the system and determine if the concern is still present.

Is the concern still present?







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