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DTC P0461: Fuel Level Sensor #1 Performance: Testing

    NOTE: Diagnose DTC P0462 or P0463 first, if set along with P0460. See DIAGNOSTIC TROUBLE CODE DEFINITIONS . Inspect the Fuel Pump Module harness connector for any corrosion or damage.
  1. Turn the ignition on. With the DRBIII®, read DTCs and record the related Freeze Frame data. Is the Good Trip counter displayed and equal to zero? If yes, go to next step. If no, go to step  8.
  2. Visually inspect the Fuel Tank for damage that may restrict the Fuel Sending Unit float from moving. Is the Fuel Tank okay? If yes, go to next step. If no, replace the Fuel Tank as necessary.
  3. Turn the ignition off. Disconnect the Fuel Pump Module harness connector. Measure the resistance between ground and the Fuel Level Sensor Signal circuit in the Fuel Pump Module harness connector. Is the resistance below 100 ohms? If yes, repair the short to ground in the Fuel Level Sensor Signal circuit. If no, go to next step.
  4. Turn ignition off. Disconnect Body Control Module (BCM) Blue C4 harness connector. The BCM is mounted to junction block. Junction block is located behind left end cap of instrument panel. Measure resistance of Fuel Level Sensor Signal circuit (Dark Blue wire) between Fuel Pump Module harness connector and terminal No. 7 at BCM C4 harness connector. Is the resistance below 5 ohms? If yes, go to next step. If no, repair the open in the Fuel Level Sensor Signal circuit.
  5. Measure the resistance between ground and the Ground circuit in the Fuel Pump Module harness connector. Is the resistance below 5.0 ohms? If yes, go to next step. If no, repair the open in the Ground circuit.
    6. WARNING: The fuel system is under a constant pressure, even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. See FUEL SYSTEM PRESSURE RELEASE .
  6. Turn the ignition off. Remove the fuel tank. See FUEL TANK under FUEL SYSTEMS in appropriate REMOVAL, OVERHAUL & INSTALLATION article. Remove the fuel pump module from the fuel tank. Inspect the inside of the fuel tank for any obstructions or deformities. Inspect the Fuel Pump Module float arm for damage. Were any problems found? If yes, repair or replace as necessary. If no, go to next step.
  7. There are no possible causes remaining, replace the fuel level sensor. Replace 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 appropriate REMOVAL, OVERHAUL & INSTALLATION article.
    8. 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.
  8. 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. 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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