Instruments - MIL ON/Fuel Gauge Reads Too High/DTC P0461
No. TSB-07-13-009DATE: November, 2007
MODEL: 2008 Lancer
SUBJECT:
FUEL GAUGE ALWAYS READS HIGH OR DTC P04611
PURPOSE
On a small number of affected vehicles, the fuel level float arm may contact a vapor hose inside the fuel tank causing the arm to stick in the full position regardless of the amount of fuel in the tank. The customer will complain that the MIL is illuminated. They may also complain that the fuel gauge does not change in relation to the number of miles driven. This TSB provides instructions to install a modified fuel level float arm assembly.
AFFECTED VEHICLES
2008 Lancer built prior to September 17, 2007.
REPAIR PROCEDURE
CAUTION
If the fuel tank is full, some fuel may be lost when removing the fuel pump.
REMOVAL
CAUTION
Fuel vapors are flammable. Insure that no ignition sources (open flame, sparks, etc.) are present when performing these steps. Disconnect the negative terminal of the battery prior to removing the fuel pump from the vehicle.
1. Remove the fuel pump module from the vehicle as per instructions in the service manual.
Using the following steps, replace the fuel level float arm.
2. Disconnect the electrical connector with 3 black wires and 1 red wire.
3. Carefully remove the thermistor from its retaining
clip.
4. Disengage the retaining clip and slide the arm assembly in the direction of the electrical connector as indicated.
5. Carefully remove the thermistor wires from the retaining clip.
6. Lift the fuel level gauge assembly away from the pump.
INSTALLATION
Installation is the reverse of Removal
1. Insert the black thermistor wires under their retaining clip.
2. Position the fuel level gauge arm assembly and slide it towards the bottom of the fuel pump assembly as indicated until the retaining clip
engages.
3. Resecure the thermistor in its retaining clip and reconnect the connector.
4. Using an ohmmeter, check resistance of the fuel level sensor (terminals 1 & 2) when moving the arm. You should read a smooth linear change in resistance.
5. Install the fuel pump module as per instructions in the service manual. Reconnect the electrical connector and the battery negative terminal.
6. With the scan tool, select Read and Erase All DTCs. Address any DTCs that may occur using service manual diagnostics.
PARTS INFORMATION
WARRANTY INFORMATION
This bulletin is supplied as technical information only and is not an authorization to repair.
If an affected vehicle is observed with the described condition, diagnose the condition, and if confirmed, repair as described in this bulletin and submit a normal warranty claim as follows.