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DTC P0462: Fuel Level Sending Unit Volts Too Low: Testing

  1. Turn ignition on, engine not running. With the DRBIII®, read the fuel level sensor voltage. Is the fuel level sensor voltage below 0.2 volt? If yes, go to next step. If no, go to step  6.
  2. Turn the ignition off. Disconnect the Fuel Pump Module harness connector. Fuel pump module is mounted in top of fuel tank. Turn ignition on, engine not running. With the DRBIII®, read the Fuel Level Sensor voltage. Did the Fuel Level Sensor voltage change from below 0.2 volt to above 4.5 volts? If yes, replace the fuel level sensor. Fuel level sensor is located on fuel pump module and can be replaced separately. See FUEL LEVEL SENSOR under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION article. If no, go to next step.
  3. Turn the ignition off. Disconnect PCM harness connectors. Check connectors and clean/repair as necessary. Measure the resistance between ground and the Fuel Level Sensor Signal circuit at Fuel Pump Module harness connector. Is the resistance below 100 ohms? If yes, repair the fuel level sensor signal circuit for a short to ground. If no, go to next step.
  4. Ensure fuel pump module and the PCM are disconnected. Measure the resistance between the Fuel Level Sensor Signal circuit and the Sensor Ground circuit at the fuel pump module harness connector. Is the resistance below 100 ohms? If yes, repair the fuel level sensor signal circuit for a short to the sensor ground circuit. If no, go to next step.
  5. There are no possible causes remaining, replace PCM. Program the new PCM. See PROGRAMMING .
    6. WARNING: When the engine is operating, do not stand in a direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing.
  6. The conditions that set the DTC are not present at this time. The following may help in identifying the intermittent condition. With the engine running at normal operating temperature, monitor the DRBIII® parameters related to the DTC while wiggling the wiring harness. Look for parameter values to change and/or a DTC to set. Review the DRBIII® Freeze Frame information. If possible, try to duplicate the conditions under which the DTC was set. Refer to any Technical Service Bulletins (TSB) that may apply. With the DRBIII® as a Dual Channel Lab Scope and the Miller Special Tool (6801), backprobe the Fuel Level Signal circuit at the Fuel Pump Module connector and PCM connector. Turn the ignition on and look for any differences in the two patterns. Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or partially broken wires. Visually inspect the related wiring harness connectors. Look for broken, bent, pushed out, or corroded terminals. Were any of the above conditions present? If yes, repair as necessary. If no, test is complete.
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