881353 Mercury CLAMP

Table 1
Diagnostic Codes Table
Code and Description Conditions which Generate this Code System Response
96-3
Fuel Level Sensor voltage above normal The voltage on the signal wire for the fuel level sensor is above normal. The code is logged.
96-4
Fuel Level Sensor voltage below normal The voltage on the signal wire for the fuel level sensor is below normal. When the fuel tank is full, the fuel level sensor has a resistance of 33 Ohms. When the fuel tank is empty, the fuel level sensor has a resistance of 240 Ohms. The resistance from the fuel level sensor varies between these values as the fuel level varies.The variable resistance of the sensor affects the pull-up voltage that is created by the ECM. When the resistance of the sensor is low, the pull-up voltage is low. When the resistance of the sensor is high, the pull-up voltage is high. Refer to Table 2.
Table 2
Relationship Between the Resistance of the Sensor and the Voltage on the Signal Wire
Fuel Level Resistance Approximate Voltage on the Signal Wire
Full 33 Ohms 0.15 VDC
Empty 240 Ohms 1.8 VDC The most likely electrical problem with the circuit for the fuel level sensor is a problem in the wiring harness. The next likely cause is a problem with the fuel level sensor. The least likely cause is a problem with the ECM.
Table 3
Troubleshooting Test Steps Expected Results Results
1. Inspect the Electrical Connectors and the Wiring
A. Remove the electrical power from the ECM.
B. Thoroughly inspect connectors (1) and (2). Refer to Troubleshooting, "Electrical Connectors-Inspect" for details.
C. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the fuel level sensor.
D. Check the allen head screw on each of the ECM connectors for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
E. Check the harness and the wiring for abrasion and for pinch points from the fuel level sensor to the ECM.
All connectors, pins, and sockets are coupled and/or inserted and the harness and wiring are free of corrosion, of abrasion and of pinch points.
Result: The connectors and the wiring are OK.
Proceed to Test Step 2.
Result: There is a problem in the connectors and/or the wiring.
Repair the connectors and/or the wiring. Replace parts, if necessary. Verify that the repair eliminates the problem.
2. Check the Resistance of the Sensor at the Harness Connector
A. Disconnect the fuel sensor at the harness connectors.
B. Measure the resistance of the sensor between terminal 1 (fuel level) and terminal 2 (sensor return) at the harness connector. Record the measurement.
The resistance measurement of the sensor is between 33 and 240 Ohms.
Result: The resistance measurement is between 33 and 240 Ohms. Connect the harness connectors that are for the fuel level sensor. The resistance of the sensor is OK.
Proceed to Test Step 3.
3. Check the Resistance of the Sensor Through the Harness
A. Remove the wire from terminal location J1:33 for the fuel level sensor from the ECM connector in order to isolate the circuit.
B. Install a 7X-1709 Multimeter Probe (BLACK) into terminal location J2:11 (sensor return) at the ECM connector.
Ensure that the multimeter probe is in good repair. A bent probe may contact other terminals inside the connector.
C. Measure the resistance between the loose wire and the multimeter probe at the ECM connector. Record the measurement.
Be sure to wiggle the harness during the measurement in order to reveal an intermittent electrical condition in the harness.
The resistance measurement of the sensor through the harness is between 33 and 240 Ohms.
Result: The resistance measurement is between 33 and 240 Ohms.
The resistance of the sensor is OK and the vessel's wiring is OK. The resistance of the sensor and the resistance through the wiring harness is OK. There appears to be a problem with the ECM. Replace the ECM. Refer to Troubleshooting, "ECM - Replace" for details.
Result: The resistance measurement of the sensor through the harness is not between 33 and 240 Ohms.
The resistance of the sensor at the sensor connector is within specifications. The resistance of the sensor through the harness is not within specifications. There is a problem in the wiring harness that is between the ECM connector and the sensor connector. There may be a problem with a connector. Repair the wiring, when possible. Replace parts, if necessary. Verify that the problem is resolved.
Complete the procedure in the order in which the steps are listed.The procedure corrected the issue. - STOPResult: This procedure did not correct the issue.Contact your Cat dealer Technical Communicator (TC). For further assistance, your TC can confer with the Dealer Solutions Network (DSN).