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Home >> Mitsubishi >> 2003 >> Montero XLS >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - Self-Diagnostics >> Diagnostic Tests >> DTC P0461: Fuel Level Sensor Circuit Range/Performance >> Diagnostic Procedure

Diagnostic Procedure

CAUTION: To prevent damage to scan tool (MB991502), always turn the ignition off before connecting or disconnecting it.
  1. Using scan tool (MB991502), check data list item 4B: FUEL LEVEL SENSOR. Connect scan tool (MB991502) to the data link connector. Turn the ignition switch to the "ON" position. Set scan tool (MB991502) to the data reading mode for item 4B: FUEL LEVEL SENSOR. When the fuel gauge is near "FULL", voltage should be 100-3600 millivolts. When the fuel gauge is near "EMPTY", voltage should be 2700-6200 millivolts. Turn the ignition switch to the "LOCK" (OFF) position. If the sensor is operating properly, it can be assumed that this malfunction is intermittent. Refer to INTERMITTENT DIAGNOSTIC TROUBLE CODES , otherwise, go to the next step.
  2. Check connector G-03 at the fuel level sensor for damage. If the connector is in good condition, go to the next step, otherwise, repair or replace it. Then go to step  12.
  3. Check the continuity at fuel level sensor harness side connector G-03. Disconnect the connector G-03 and measure at the harness side. Check for the continuity between terminal No. 2 and ground. Should be less than 2 ohms. If the continuity is normal, go to the next step, otherwise, check connector F-07 at intermediate connector for damage, and repair or replace as required. If intermediate connector is in good condition, repair harness wire between fuel level sensor connector G-03 (terminal No. 2) and ground because of open circuit or harness damage. Then go to step  12.
  4. Measure the sensor supply voltage at fuel level sensor harness side connector G-03. Disconnect the connector G-03 and measure at the harness side. Disconnect the combination connector D-03. Turn the ignition switch to the "ON" position. Measure the voltage between terminal No. 1 and ground. Voltage should be battery positive voltage (approximately 12 volts). Turn the ignition switch to the "LOCK" (OFF) position. If battery positive voltage is present, go to step  9, otherwise, go to the next step.
  5. Measure the sensor supply voltage at PCM connector D-134 by backprobing. Do not disconnect the PCM connector D-134. Disconnect the combination meter connector D-03. Turn the ignition switch to the "ON" position. Measure the voltage between terminal No. 72 and ground by backprobing. When the fuel gauge is near "FULL", voltage should be 0.1 and 3.6 volts. When the fuel gauge is near "EMPTY", voltage should be 2.7 and 6.2 volts. Turn the ignition switch to the "LOCK" (OFF) position. If the voltage is normal, go to the next step, otherwise, go to step  7.
  6. Check connector D-134 at PCM for damage. If the connector in good condition, check connector D-111, E-113 and F-07 at intermediate connector for damage, and repair or replace as required. If intermediate connectors are in good condition, repair harness wire between fuel level sensor connector G-03 (terminal No. 1) and PCM connector D-134 (terminal No. 72) because of open circuit. Then go to step  12, otherwise, repair or replace it. Then go to step  12.
  7. Check connector D-134 at PCM for damage. If the connector is in good condition, go to the next step, otherwise, repair or replace it. Then go to step  12.
  8. Check for short circuit to ground between fuel level sensor connector G-03 (terminal No. 1) and PCM connector D-134 (terminal No. 72). If the harness wire is in good condition, replace the PCM. Then go to step  12, otherwise, repair it. Then go to step  12.
  9. Check the fuel level sensor. If the fuel level sensor is normal, go to the next step, otherwise, replace the fuel level sensor. Then go to step  12.
  10. Check connector D-134 at PCM for damage. If the connector is in good condition, go to the next step, otherwise, repair or replace it. Then go to step  12.
  11. Check for harness damage between fuel level sensor connector G-03 (terminal No. 1) and PCM connector D-134 (terminal No. 72). If the harness wire is in good condition, replace the PCM. Then go to the next step, otherwise, repair it. Then go to the next step.
  12. Test the OBD-II drive cycle. Carry out a test drive with the drive cycle pattern. See OTHER MONITOR  under OBD-II DRIVE CYCLES under DRIVE CYCLES. If DTC P0461 sets, retry the troubleshooting, otherwise, the inspection is complete.
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