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Home >> Jeep >> 2002 >> Wrangler X, Automatic >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - Self-Diagnostics >> Diagnostic Tests >> DTC P0463: Fuel Level Sending Unit Volts Too High >> Testing

DTC P0463: Fuel Level Sending Unit Volts Too High: Testing

  1. Turn ignition on, engine not running. With the DRBIII®, read the fuel level sensor voltage. Is the fuel level sensor voltage above 4.9 volts? If yes, go to next step. If no, go to step  7.
  2. Turn the ignition off. Disconnect the Fuel Pump Module harness connector. Fuel pump module is mounted in top of fuel tank. Connect a jumper wire between the Fuel Level Sensor signal circuit and the Sensor Ground circuit at the Fuel Pump Module harness connector. Turn ignition on, engine not running. With the DRBIII®, read the Fuel Level Sensor voltage. Did the Fuel Level Sensor voltage change from above 4.9 volts to below 0.4 volt? If yes, replace the fuel level sensor. If no, go to next step.
  3. Turn the ignition off. Disconnect the PCM harness connectors. Check connectors and clean/repair as necessary. Measure the resistance of the Sensor ground circuit from the PCM harness connector to the Fuel Pump Module harness connector. Is the resistance below 5.0 ohms? If yes, go to next step. If no, repair the sensor ground circuit for an open.
  4. Ensure the ignition is off. Reconnect PCM connectors. Measure the voltage of the Fuel Level Sensor Signal circuit at the Fuel Pump Module harness connector. Is the voltage above 5.3 volts? If yes, repair the fuel level sensor signal circuit short to voltage. If no, go to next step.
  5. Turn the ignition off. Disconnect the PCM harness connectors. Measure the resistance of the Fuel Level Sensor signal circuit from the PCM harness connector to the Fuel Pump Module harness connector. Is the resistance below 5.0 ohms? If yes, go to next step. If no, repair fuel level sensor signal circuit for an open.
  6. There are no possible causes remaining, replace PCM. Program the new PCM. See PROGRAMMING .
    7. 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.
  7. 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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