Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463
TSB 06-17-1009/04/06
MIL ON WITH DTC P0463 OR ERRATIC FUEL GAUGE OPERATION
FORD:
2004-2007 Explorer
MERCURY:
2004-2007 Mountaineer
This article supersedes TSB 06-16-7 to update the Service Procedure.
ISSUE
Some 2004-2007 Explorer 4dr/Mountaineer vehicles may exhibit the malfunction indicator lamp (MIL) on with diagnostic trouble code (DTC) P0463 or an erratic fuel gauge concern. This could be from sulphur contamination in the fuel, causing an open or high resistance on the fuel sender card.
ACTION
Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. For vehicles with customer symptom of erratic fuel gauge operation (with no MIL on), proceed to Step 1a. For vehicles with a customer symptom including the MIL on, proceed to Step 1b. If unable to verify the concern, do not continue with this TSB.
a. Follow the appropriate pinpoint test (PPT) for "Fuel Gauge Inaccurate" in Workshop Manual (WSM), Section 413-01. If PPT test results lead to fuel pump module replacement, proceed to Step 2. If PPT test results isolate any problem other than fuel pump module replacement, repair as indicated and do not continue with this TSB.
b. Install diagnostic scan tool to retrieve DTCs. If DTC P0463 is retrieved, proceed to Step 2. If DTC P0463 is not retrieved, this TSB does not apply, follow normal WSM diagnostics.
2. Remove fuel tank per WSM, Section 310-01.
3. Remove fuel pump assembly from fuel tank per WSM, Section 310-01. See Figure 1 (Chart) to determine if a kit (contains a fuel level sensor assembly, a wire harness and heat shrink tube) or fuel pump assembly is required for repair. For vehicles that can be serviced with a kit go to Step 4. For vehicles that require fuel pump assembly replacement, go to Step 12.
4. Remove the fuel level sensor assembly (sender card/float rod assembly) from the fuel pump assembly per WSM, Section 310-01.
5. Detach electrical connector from fuel pump housing (Figure 2).
6. Remove wiring harness from the fuel pump assembly flange by depressing the retaining fingers on the harness connector at bottom of flange and pushing upward out of flange (Figure 3).
7. Install new wiring harness by feeding wires through flange hole and inserting harness connector into flange until an audible click is heard. Check for proper retention.
8. Re-attach electrical connector harness to fuel pump housing. Prior to making the connection place one loop in the pump wires away from the convoluted feed tube (Figure 4).
9. Re-attach the signal wire (yellow) on the harness to the signal wire (yellow) on the replacement fuel level sensor assembly per WSM, Section 310-01 (Figure 5).
10. Wrap the ground wire one time around the signal wire and attach the ground wire terminal to the terminal on the fuel level sensor assembly. Check for proper retention.
NOTE
THE GROUND WIRE MUST BE WRAPPED AROUND THE SIGNAL WIRE, AS DESCRIBED IN STEP 10, TO PREVENT POTENTIAL INTERFERENCE WITH THE FLOAT ROD ARM.
11. Re-attach the fuel level sensor assembly to the fuel pump housing, making sure that both the signal wire and the ground wire are routed through the gap between the fuel level sensor assembly and fuel pump bracket. Torque the fastener at the bottom of the fuel level sensor assembly to 1 N.m (9 lb-in).
12. Re-install fuel pump assembly into fuel tank per WSM, Section 310-01.
NOTE
TAKE CARE NOT TO DAMAGE/BEND FLOAT ROD OR SENDER CARD DURING INSTALLATION OF FUEL PUMP ASSEMBLY.
13. Re-install fuel tank per WSM, Section 310-01.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
061710A 2004-2007 2.9 Hrs.
Explorer/Mountaineer:
Diagnose And Replace
The Fuel Gauge Tank Unit
(Do Not Use With 9275D,
9275A, 9002A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
9A299 28
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