DTC P0461: FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM Subaru Outback BH

Perform basic diagnostic procedure. See BASIC DIAGNOSTIC PROCEDURE . If DTC P0461 is only DTC set, replace fuel sending unit and fuel sub level sensor assembly. If DTC P0462 or P0463 also exist, diagnose and repair those codes. Do not diagnose DTC P0461. Clear memory and perform verification procedure. See CLEARING DIAGNOSTIC TROUBLE CODES and VERIFICATION PROCEDURE .

Scheme 70

Scheme 71

1. Perform basic diagnostic procedure. See «BASIC DIAGNOSTIC PROCEDURE»(ref-63535-S26517940312001020900000). Check speedometer and tachometer operation. If speedometer and tachometer operate normally, go to next step. If speedometer and tachometer do not operate normally, repair or replace instrument cluster.
2. Turn ignition on. Using DVOM connected to ground, backprobe ECM connector B135 (28-pin connector) terminal No. 25. see scheme 4 If voltage is not less than 0.12 volt, go to next step. If voltage is less than 0.12 volt, go to step 4.
3. Using scan tool, read fuel level sensor signal while wiggling harness and ECM connector. If voltage changes less than 0.12 volt while wiggling harness and ECM connector, repair poor terminal contact in ECM connector. If voltage does not change less than 0.12 volt while wiggling harness and ECM connector, circuit has returned to normal. Check for poor terminal contact in connectors between instrument cluster and ECM.
4. Turn ignition off. Remove service hole cover located in left rear of luggage compartment floor. Disconnect Black 6-pin in-line connector located between rear wiring harness and fuel tank harness (nearest fuel tank). Turn ignition on. Using DVOM connected to ground, backprobe ECM connector B135 (28-pin connector) terminal No. 25. If voltage is not more than 0.12 volt, go to step 7. If voltage is more than 0.12 volt, go to next step.
5. Turn ignition off. Disconnect ECM connector B135 (28-pin connector) and 30-pin instrument panel electrical harness connector. (Scheme 70) Using an ohmmeter connected to ground, backprobe ECM connector B135 (28-pin connector) terminal No. 25. If resistance is more than one megohm, go to next step. If resistance is not more than one megohm, locate and repair short to ground in wiring between ECM and instrument cluster. See WIRING DIAGRAMS article.
6. Measure resistance between ECM connector B135 (28-pin connector) terminal No. 25 and 30-pin instrument cluster connector terminal No. 3. If resistance is not less than 10 ohms, locate and repair open circuit in wiring and check for poor terminal contact in connectors between ECM and instrument cluster. If resistance is less than 10 ohms, repair or replace instrument cluster.
7. Turn ignition off. Disconnect fuel sub level sensor 2-pin connector. Measure resistance between ground and fuel sub level sensor connector terminal No. 1. (Scheme 71) If resistance is more than one megohm, go to next step. If resistance is not more than one megohm, locate and repair short to ground in fuel tank harness.
8. Disconnect electrical connector at fuel pump. With fuel sub level sensor 2-pin connector still disconnected, use ohmmeter to measure resistance between ground and fuel sub level sensor connector terminal No. 2. If resistance is not more than one megohm, locate and repair short to ground in fuel tank harness. If resistance is more than one megohm, go to next step.
9. Remove fuel pump assembly from fuel tank. With fuel level sensor float set to full position, measure resistance between terminals No. 3 and No. 6 of fuel level sensor. If resistance is between 0.5 and 2.5 ohms, go to next step. If resistance is not between 0.5 and 2.5 ohms, replace fuel level sensor.
10. Remove fuel sub level sensor. With fuel sub level sensor float set to full position, measure resistance between terminals of fuel sub level sensor. If resistance is between 0.5 and 2.5 ohms, repair poor terminal contact in connectors between ECM and instrument cluster. If resistance is not between 0.5 and 2.5 ohms, replace fuel sub level sensor. Clear memory and perform verification procedure. See «CLEARING DIAGNOSTIC TROUBLE CODES»(ref-63535-S26931138132001020900000) and «VERIFICATION PROCEDURE»(ref-63535-S38101445392001020900000).

Scheme 72

Scheme 73

1. Perform basic diagnostic procedure. See «BASIC DIAGNOSTIC PROCEDURE»(ref-63535-S26517940312001020900000). Check speedometer and tachometer operation. If speedometer and tachometer operate normally, go to next step. If speedometer and tachometer do not operate normally, repair or replace instrument cluster.
2. Turn ignition on. Using DVOM connected to ground, backprobe ECM connector B135 (28-pin connector) terminal No. 25. see scheme 4 If voltage is more than 4.75 volts, go to next step. If voltage is not more than 4.75 volts, system has returned to normal. Check for poor terminal contact in connectors between fuel pump, ECM and instrument cluster.
3. Turn ignition off. Disconnect 30-pin instrument panel electrical harness connector and ECM connector B135 (28-pin connector). see scheme 4and (Scheme 70). Using DVOM connected to ground, backprobe ECM connector B135 (28-pin connector) terminal No. 25. If voltage is more than 4.75 volts, go to next step. If voltage is not more than 4.75 volts, locate and repair short to voltage in wiring between ECM and instrument cluster. See WIRING DIAGRAMS article.
4. Turn ignition off. Remove service hole cover located in left rear of luggage compartment floor. Disconnect Black 6-pin in-line connector located between rear wiring harness and fuel tank harness (nearest fuel tank). Measure resistance between ECM connector B135 (28-pin connector) terminal No. 25 and ECM-side of Black 6-pin in-line connector terminal No. 6. see scheme 4and (Scheme 72). If resistance is less than 5 ohms, go to next step. If resistance is not less than 5 ohms, repair open circuit in wiring between ECM and fuel tank.
5. Measure resistance between ground and ECM-side of Black 6-pin in-line connector terminal No. 5. If resistance is less than 5 ohms, go to next step. If resistance is not less than 5 ohms, locate and repair open circuit in wiring and check for poor terminal contact in connectors between fuel tank and ground.
6. Disconnect 6-pin electrical connector from fuel level sensor. Using an ohmmeter, measure resistance between fuel level sensor terminal No. 3 and fuel tank-side of Black 6-pin in-line connector terminal No. 5. (Scheme 73) If resistance is less than 10 ohms, go to next step. If resistance is not less than 10 ohms, locate and repair open in wiring and check for poor terminal contact in connectors between Black 6-pin in-line harness connector and fuel level sensor.
7. Turn ignition off. Disconnect 2-pin connector from fuel sub level sensor. Using an ohmmeter, measure resistance between 6-pin fuel level sensor harness connector terminal No. 6 and fuel sub level sensor connector terminal No. 2. see scheme 9and (Scheme 71). If resistance is less than 10 ohms, go to next step. If resistance is not less than 10 ohms, locate and repair open circuit in wiring between fuel level sensor and fuel sub level sensor.
8. Measure resistance between 2-pin fuel sub level sensor harness connector terminal No. 1 and fuel tank-side of Black 6-pin in-line connector terminal No. 6. (Scheme 71)and (Scheme 73). If resistance is less than 10 ohms, go to next step. If resistance is not less than 10 ohms, locate and repair open circuit in wiring between fuel tank harness and fuel sub level sensor.
9. Remove fuel pump assembly from fuel tank. While moving fuel level sensor float up and down, measure resistance across terminals No. 3 and No. 6 of fuel level sensor. If resistance is more than 54.5 ohms, replace fuel level sensor. If resistance is not more than 54.5 ohms, go to next step.
10. Remove fuel sub level sensor. While moving fuel sub level sensor float up and down, measure resistance across fuel sub level sensor terminals. If resistance is more than 41.5 ohms, replace fuel sub level sensor. If resistance is not more than 41.5 ohms, replace instrument cluster. Clear memory and perform verification procedure. See «CLEARING DIAGNOSTIC TROUBLE CODES»(ref-63535-S26931138132001020900000) and «VERIFICATION PROCEDURE»(ref-63535-S38101445392001020900000).