Note. For connector terminal identification, see CONNECTOR IDENTIFICATION . For circuit identification and wiring diagram, see CHEROKEE wiring diagram in WIRING DIAGRAMS article.
Note. DTC P0463: FUEL LEVEL SENDING UNIT VOLTS TOO HIGH is monitored with ignition on and battery voltage more than 10.4 volts. DTC may be stored in Powertrain Control Module (PCM) if 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.
- Turn ignition on, with engine off. Using scan tool, read FUEL LEVEL SENSOR voltage. If voltage is more than 9.4 volts, go to next step. If voltage is 9.4 volts or less, go to step 6).
- 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 level sensor signal circuit (Dark Blue/Light Green wire) and sensor ground circuit (Brown/Yellow wire). Turn ignition on, with engine off. Using scan tool, read FUEL LEVEL SENSOR voltage. If voltage is one volt or more, go to next step. If voltage is less than one volt, replace fuel level sensor. Fuel level sensor is located in fuel pump module. Perform TEST VER-2A.
- Turn ignition off. Ensure fuel pump module connector is still disconnected. Connect a jumper wire between ground and fuel pump module connector, fuel level sensor signal circuit (Dark Blue/Light Green wire). Turn ignition on, with engine off. Using scan tool, read FUEL LEVEL SENSOR voltage. If voltage is less than one volt, repair open sensor ground circuit (Brown/Yellow wire). Perform TEST VER-2A. If voltage is one volt or more, go to next step.
- 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 ohmmeter, check resistance of fuel level sensor signal circuit (Dark Blue/Light Green wire) between fuel pump module connector and PCM. If resistance is less than 5 ohms, go to next step. Perform TEST VER-2A. If resistance is 5 ohms or more, repair open fuel level sensor signal circuit. Perform TEST VER-2A.
- At this time, PCM is assumed to be defective. Replace PCM. Perform TEST VER-2A.
- Ensure ignition is on, with engine off. Using scan tool, monitor FUEL LEVEL SENSOR voltage while wiggling fuel pump module connector and wiring harness. Fuel pump module is located in fuel tank. If voltage changes while wiggling wiring harness, repair 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.
- 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.