TURBOCHARGER GP 3407184 - Caterpillar

Illustration 4 g01155187
P803 Fuel level sensor connector (P803-1) Fuel level (P803-2) Sensor return
Perform a 45 N (10 lb) pull test on each of the wires that are associated with the fuel level sensor.
Check the allen head screw on the ECM connectors for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
Check the harness and the wiring for abrasion and for pinch points from the fuel level sensor to the ECM.Expected Result:All connectors, pins and sockets are completely coupled and/or inserted and the harness and wiring are free of corrosion, of abrasion and of pinch points.Results:
OK - The connectors and the wiring appear to be OK. Proceed to Test Step 2.
Not OK - There is a problem in the connectors and/or the wiring.Repair: Repair the circuit. Verify that the repair eliminates the problem.STOPTest Step 2. Confirm the Fuel Level in the Tank
Visually check the fuel level in the tank.
Compare the fuel level in the tank to the indicator on the fuel level sender.Expected Result:The fuel level in the tank agrees with the indicator on the fuel level sender.Results:
OK - Proceed to Test Step 3.
Not OK - The indicator on the fuel level sender does not reflect the actual fuel level in the tank.Repair: Replace the fuel level sender. Verify that the repair eliminates the problem.STOPTest Step 3. Check the Status of the Fuel Level
Turn the keyswitch to the OFF position.
Connect the Caterpillar Electronic Technician (ET) to the service tool connector.
Turn the keyswitch to the ON position.
Observe the status of "Fuel Gauge" on Cat ET.Note: The "Fuel Gauge" on Cat ET represents the percentage of fuel level in the tank.
Turn the keyswitch to the OFF position.Expected Result:The status of "Fuel Gauge" displays the correct fuel level.Results:
OK - Cat ET displays the correct fuel level.Repair: The fuel level sensor appears to be operating correctly at this time. There may be an intermittent problem in the harness or in a connector. Refer to Troubleshooting, "Electrical Connectors - Inspect" if the problem is intermittent.STOP
Not OK - Cat ET does not display the correct fuel level. Proceed to Test Step 4.Test Step 4. Check the Resistance of the Fuel Level Sender
Disconnect the fuel level sender from the fuel level buffer.
Measure the resistance between the terminals on the receptacle for the fuel level sender.The correct resistance is between 0 and 3.5 Ohms when the indicator is on "F". The correct resistanceis between 92 and 98 Ohms when the indicator is on "E".
Reconnect the fuel level sender.Expected Result:The resistance is less than 98 Ohms.Results:
OK - The resistance is less than 98 Ohms. The fuel level sender appears to be OK. Proceed to Test Step 5.
Not OK - The resistance is out of the range.Repair: Replace the fuel level sender. Verify that the repair eliminates the problem.STOPTest Step 5. Check the Supply Voltage to the Buffer
Disconnect the connector at the fuel level buffer.
Turn the keyswitch to the ON position.
Measure the voltage across terminal A (+Battery) and terminal B (digital return) at the