Electronics/Fuel System - MIL ON/DTC P0460 Set

Article No.
03-1-7

01/20/03

^ DRIVEABILITY - MIL (MALFUNCTION INDICATOR
LIGHT) WITH DTC P0460 (FUEL LEVEL SENSOR
CIRCUIT ERROR) - SERVICE TIPS

^ ELECTRICAL - MIL (MALFUNCTION INDICATOR
LIGHT) WITH DTC P0460 (FUEL LEVEL SENSOR
CIRCUIT ERROR) - SERVICE TIPS

FORD:
2002 THUNDERBIRD

LINCOLN:
2002 LS

ISSUE
Some vehicles may exhibit an illuminated MIL with DTC P0460. This may be caused by a fuel level indicator circuit condition or an inoperative fuel level sending unit.

ACTION
Diagnose and repair the vehicle as needed using the following Service Procedure.

SERVICE PROCEDURE

NOTE
ALL THE FOLLOWING TESTS MUST BE PERFORMED WITH THE KEY OFF.

1. Check the condition of G401 & G402 (G402 only on Lincoln LS). It may be necessary to completely disassemble the ground by removing the ground fastener to inspect for corrosion and damaged terminals. Torque fastener to 9 Lb-ft (12 N.m). Service as needed to correct, or continue with the article as needed.

2. Gain access to the FDM (Fuel Delivery Module) and JPM (Jet Pump Module). Check for signs of damage to connector and wiring. Check that connector is secure. Check for bent pins/terminals in connector. Refer to Workshop Manual, Section 310-00 for details. Service as needed to correct, or continue with the article as needed.

3. Gain access to the REM (Rear Electronics Module). Check for signs of damage to connectors and wiring. Check that connectors are secure. Check for bent pins/terminals in connectors. Refer to Workshop Manual, Section 419-10 for details. Service as needed to correct, or continue with the article as needed.





4. Disconnect all electrical connectors at JPM, FDM and REM. Check for resistance less than 1 ohm between the following connector pins. Service as needed to correct, or continue with the article as needed.

a. JPM C434 Pin 2 - REM C420d Pin 16
(C420e Thunderbird)

b. JPM C434 Pin 3 - REM C420c Pin 23
(C420f Thunderbird)

c. FDM C433 Pin 3 - REM C420c Pin 23
(C420f Thunderbird)

d. FDM C433 Pin 2 - REM C420d Pin 15
(C420e Thunderbird)

5. Connectors remaining disconnected, check for voltage (short to power) and continuity to ground (meter must indicate open circuit) at the following pins. Service as needed to correct, or continue with the article as needed.

a. JPM C434 Pin 2

b. JPM C434 Pin 3

c. FDM C433 Pin 3

d. FDM C433 Pin 2

6. Remove the JPM from the left/driver side of fuel tank. Refer to Workshop Manual, Section 310-00 for details.

7. Check the resistance through the sending unit on the JPM. With the float at empty stop (bottom), steadily lift the float arm to the full stop (top) while carefully monitoring the resistance values. The resistance value at the bottom stop should be 19 ohms (+/- 2) and should reach 155 ohms (+/- 2) at the full stop. The resistance value should increase in a smooth, progressive fashion. If at any time during the resistance check the value becomes erratic or indicates outside the specifications, replace the JPM with Part Number YW4Z-9275-BC. If resistance values are acceptable, install the JPM and continue with Step 8.

8. Remove the FDM from the right/passenger side of fuel tank. Refer to Workshop Manual, Section 310-00 for details.

9. Check the resistance through the sending unit on the FDM, pins 2 and 3 on C433. With the float at empty stop (bottom), steadily lift the float arm to the full stop (top) while carefully monitoring the resistance values. The resistance value at the bottom stop should be 15 ohms (+/- 2) and should reach 160 ohms (+/- 2) at the full stop. The resistance value should increase in a smooth, progressive fashion. If at any time during the resistance check the value becomes erratic or indicates outside the specifications, replace the FDM with Part Number YW4Z-9H307-BA.

10. The operation of the fuel gauge may also be used to determine a concern with fuel sending units. If the JPM sending unit is open (high resistance), the fuel gauge will default to the FDM sending unit input only. The fuel gauge will then indicate 1/2 (with a full fuel tank). If the fuel gauge drops to Empty, this would indicate the FDM sending unit is open (high resistance).

OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 204000, 204200, 206000, 698298





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