DTC P0463: FUEL LEVEL SENDING UNIT VOLTS TOO HIGH Dodge Ram Van B2500

Note. For connector terminal identification, see CONNECTOR IDENTIFICATION . For circuit identification and wiring diagram, see RAM VAN & RAM WAGON wiring diagram in WIRING DIAGRAMS article.

Note. DTC P0463: FUEL LEVEL SENDING UNIT VOLTS TOO HIGH is monitored with ignition on and with battery voltage more than 10.4 volts. DTC may be stored in Powertrain Control Module (PCM) when PCM senses fuel level sensor signal more than 9.4 volts for 2 seconds. Possible causes are: defective fuel level sensor, defective PCM, defective connector or defective wiring.

1. Turn ignition on, with engine off. Using scan tool, read FUEL LEVEL SENDING UNIT voltage. If voltage is more than 9.4 volts, go to next step. If voltage is 9.4 volts or less, go to step 8).
2. Turn ignition off. Disconnect fuel pump module connector. Fuel pump module is located in fuel tank. Clean and/or repair connector as necessary. Connect a jumper wire between fuel pump module connector, fuel sensor signal circuit (Light Blue/Black wire) and sensor ground circuit (Black/Light Blue wire). Turn ignition on, with engine off. Using scan tool, read FUEL LEVEL SENDING UNIT voltage. If voltage is less than one volt, go to next step. If voltage is one volt or more, go to step 5). NOTE: Fuel tank must be lowered to remove fuel pump module. Partially draining fuel tank may be necessary prior to removal. Fuel system may be under high pressure. Release fuel pressure prior to opening fuel system.
3. Turn ignition off. Ensure fuel pump module connector is still disconnected. Remove fuel pump module. Position fuel gauge float in up (full) position. Using an ohmmeter, check resistance between fuel pump module, fuel level sensor signal circuit (Light Blue/Black wire) and sensor ground circuit (Black/Light Blue wire). If resistance is not 10-30 ohms, go to next step. If resistance is 10-30 ohms, replace fuel pump module wiring harness. Perform TEST VER-2A.
4. At this time, fuel level sensor is assumed defective. Replace fuel level sensor. Fuel sensor is located in fuel pump module. Perform TEST VER-2A.
5. Turn ignition off. Disconnect fuel pump module connector. Clean and/or repair connector as necessary. Connect a jumper wire between ground and fuel pump module connector, fuel level sensor signal circuit (Light Blue/Black wire). Turn ignition on, with engine off. Using scan tool, read FUEL LEVEL SENDING UNIT voltage. If voltage is less than one volt, repair open sensor ground circuit. Perform TEST VER-2A. If voltage is one volt or more, go to next step.
6. Turn ignition off. Ensure fuel pump module connector is still disconnected. Disconnect PCM connectors. PCM is located in engine compartment. See PCM LOCATION table under SYSTEM DIAGNOSTICS. Clean and/or repair connectors as necessary. Using an ohmmeter, check resistance of fuel level sensor signal circuit (Light Blue/Black wire) between fuel pump module connector and PCM. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open fuel level sensor signal circuit. Perform TEST VER-2A.
7. At this time, PCM is assumed to be defective. Replace PCM. Perform TEST VER-2A.
8. Turn ignition on, with engine off. Using scan tool, monitor FUEL LEVEL SENDING UNIT voltage while wiggling fuel pump module connector and wiring harness. If voltage changes while wiggling connector and wiring harness, repair connector and wiring harness where wiggling caused voltage to change. Perform TEST VER-2A. If voltage does not change while wiggling wiring harness, go to next step.
9. Visually inspect related connectors and wiring harness for damage. Repair connectors and wiring harness as necessary. Perform TEST VER-2A. If connectors and wiring harness are okay, test is complete.