For 1990-2009 cars

### Circuit Description

The fuel level sensor changes resistance based on fuel level. The fuel level sensor has a signal circuit and a ground circuit. The engine control module (ECM) applies 5 volts on the signal circuit to the sensor. The ECM monitors the changes in this voltage caused by changes in the resistance of the sensor in order to determine fuel level.

When the fuel tank is full, the sensor resistance is low, and the ECM signal voltage is high. When the fuel tank is empty, the sensor resistance is high, and the signal voltage is low.

The ECM uses inputs from the fuel level sensor in order to calculate the total fuel percentage remaining in the fuel tank. The ECM uses the fuel level information for the evaporative emission (EVAP) and misfire diagnostics. The fuel level information is sent to the instrument panel cluster (IPC).

If the ECM detects a signal voltage higher than the operating range of the sensor, this DTC sets.

### DTC Descriptor

This diagnostic procedure supports the following DTC:

DTC P0463 Fuel Level Sensor Circuit High Voltage

### Conditions for Running the DTC

• | The engine is running.

• | DTC P0463 runs continuously once the above conditions are met.

### Conditions for Setting the DTC

• | The fuel level signal voltage is more than 4.25 volts.

• | The above condition is present for more than 10 seconds.

### Action Taken When the DTC Sets

• | The control module illuminates the malfunction indicator lamp (MIL) when the diagnostic runs and fails.

• | The control module records the operating conditions at the time the diagnostic fails. The control module stores this information in the Freeze Frame/Failure Records.

• | The fuel gage defaults to empty.

### Conditions for Clearing the MIL/DTC

• | The control module turns OFF the MIL after 3 consecutive ignition cycles that the diagnostic runs and does not fail.

• | A current DTC, Last Test Failed, clears when the diagnostic runs and passes.

• | A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic.

• | Clear the MIL and the DTC with a scan tool.

### Diagnostic Aids

Use the Freeze Frame and/or Failure Records data in order to locate an intermittent condition. If you cannot duplicate the DTC, the information included in the Freeze Frame and/or Failure Records data may aid in determining the number of miles since the DTC set. The Fail Counter and Pass Counter can also aid in determining the number of ignition cycles that the diagnostic reported a pass and/or fail. Operate the vehicle within the same freeze frame conditions (RPM, load, vehicle speed, temperature, etc.). This will isolate when the DTC failed.

### Test Description

The number below refers to the step number on the diagnostic table.

1. This step determines if the fault is present.

Step | Action | Value | Yes | No
--- | --- | --- | --- | ---
Schematic Reference: Instrument Cluster Schematics Connector End View Reference: Displays and Gages Connector End Views
1 | Did you perform the Diagnostic System Check - Vehicle? | -- | Go to Step 2 | Go to Diagnostic System Check - Vehicle
2 |

1. Turn ON the ignition, with the engine OFF.
2. Observe the Fuel Level Sensor voltage parameter with a scan tool.

Is the voltage parameter less than the specified value?

0.25 V

Go to Step 4

Go to Step 3

3 |

1. Observe the Freeze Frame/Failure Records for this DTC.
2. Turn OFF the ignition for 30 seconds.
3. Start the engine.
4. Operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records.

Did the DTC fail this ignition?

--

Go to Step 4

Go to Diagnostic Aids

4 |

1. Disconnect the fuel level sensor through the access panel under the rear seat.
2. Connect a 3-amp fused jumper wire between the signal circuit of the fuel level sender and the low reference circuit of the fuel level sender female terminal side.
3. Turn ON the ignition, with the engine OFF.
4. Observe the Fuel Level Sensor voltage parameter with a scan tool.

Is the voltage more than the specified value?

0.25 V

Go to Step 8

Go to Step 5

5 | Jumper the fuel level sensor signal circuit to a known good ground. Is the voltage more than the specified value? | 0.25 V | Go to Step 7 | Go to Step 6
6 | Test the signal circuit of the fuel level sensor for an open, for a high resistance, or for a short to voltage. Refer to Circuit Testing and Wiring Repairs . Did you find and correct the condition? | -- | Go to Step 12 | Go to Step 8
7 | Test the low reference circuit of the fuel level sensor for an open, or for a high resistance. Refer to Circuit Testing and Wiring Repairs . Did you find and correct the condition? | -- | Go to Step 12 | Go to Step 9
8 | Test for shorted terminals and poor connections at the fuel level sensor. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs . Did you find and correct the condition? | -- | Go to Step 12 | Go to Step 10
9 | Test for shorted terminals and poor connections at the engine control module (ECM). Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs . Did you find and correct the condition? | -- | Go to Step 12 | Go to Step 11
10 | Replace the fuel sender assembly. Refer to the following:

• | Fuel Pump Replacement for the 1.2L engine

• | Fuel Pump Replacement for the 1.4L DOHC engine

• | Fuel Pump Replacement for the 1.4L SOHC engine

• | Fuel Pump Replacement for the 1.5L engine

• | Fuel Sender Assembly Replacement for the 1.6L (L91) engine

Did you complete the replacement?

--

Go to Step 12

--

11 | Replace the control module. Refer to the following:

• | Engine Control Module Replacement for the 1.2L engine

• | Engine Control Module Replacement for the 1.4L DOHC engine

• | Engine Control Module Replacement for the 1.4L SOHC engine

• | Engine Control Module Replacement for the 1.5L engine

• | Engine Control Module Replacement for the 1.6L (L91) engine

Did you complete the replacement?

--

Go to Step 12

--

12 |

1. Clear the DTCs with a scan tool.
2. Turn OFF the ignition for 30 seconds.
3. Start the engine.
4. Operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records.

Did the DTC fail this ignition?

--

Go to Step 2

Go to Step 13

13 | Observe the Capture Info with a scan tool. Are there any DTCs that have not been diagnosed? | -- | Diagnostic Trouble Code (DTC) List - Vehicle | System OK