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Low Fuel Light Never/Always On

WARNING: This page is about a different car, the 1997 Mercury Sable and 1997 Ford Taurus. However, it is still accessible from the selected car via links, so may be relevant.
  1. Turn ignition to OFF position. If working on flex fuel vehicle, go to next step. If working non-flex fuel vehicle, connect Instrument Gauge System Tester (014-R1063) to circuit No. 29 (Yellow/White wire) at instrument cluster connector C250 (with connector connected). Set tester to 56 ohms. Turn ignition switch to run position, wait 60 seconds and read fuel gauge. If fuel gauge reads empty and low fuel warning light is on, replace low fuel level warning switch, fuel gauge and retest system. If gauge does not read empty, leave tester connected and go to step 3).
  2. Turn ignition to OFF position. Connect Instrument Gauge System Tester (014-R1063) to circuit No. 27 (Orange/Light Green wire) at instrument cluster connector C250 (with connector connected). Set tester to 56 ohms. Turn ignition switch to RUN position, wait 60 seconds and read fuel gauge. If fuel gauge reads empty and low fuel warning light is on, replace low fuel level warning switch, fuel gauge and retest system. If gauge does not read empty, leave tester connected and go to next step.
  3. Turn ignition switch to OFF position. Change tester setting to 25 ohms. Turn ignition switch to ON position, wait 60 seconds and read fuel gauge. If low fuel warning light is on and fuel gauge reads 16th of a tank, low fuel warning system is operating properly and no further testing is required. If low fuel warning light is not on and fuel gauge does not read 16th of a tank, go to next step.
  4. Turn ignition switch to RUN position. On non-flex fuel vehicles, connect circuit No. 29 (Yellow/White wire) between low fuel light and low fuel warning switch to ground. On flex fuel vehicles, connect circuit No. 27 (Orange/Light Green wire) between low fuel light and low fuel warning switch to ground. If low fuel level light is on, replace low fuel level warning switch, fuel gauge and retest system. If low fuel level light is not on, go to next step.
  5. Turn ignition switch to OFF position. Remove instrument cluster. See INSTRUMENT CLUSTER  under REMOVAL & INSTALLATION. Remove and inspect low fuel level indicator bulb. If bulb is okay, replace instrument cluster printed circuit and retset system. If bulb is not okay, replace bulb and retest system.
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