What does it mean?
OBD II fault code P0460 is defined as “Fuel Level Sensor Circuit Malfunction”, and is set when the PCM (Powertrain Control Module) or BCM (Body Control Module on some applications) detects a signal from the fuel level sender unit that indicates a fuel level that exceeds the fuel tank’s capacity. The PCM or BCM does not “know” how much fuel is in the fuel tank: the only information the controller has about the fuel level derives from the signal voltage generated by the sender unit.
Therefore, regardless of whether the tank is full or empty, the controller expects to see a predefined signal voltage that corresponds to that state, which means that if say, a short circuit (or any other problem) creates a resistance that is inconsistent with either state, the controller will set code P0460 and illuminate a warning light.
Put in another way, if the sender unit’s input circuit is fully functional, code P0460 will typically not be set when a mechanical problem prevents movement of the float arm. All that will happen in this case is that the fuel gauge reading will not reflect changes in the actual fuel level in the tank. In terms of operation, fuel level sender units use variable resistors to indicate the actual fuel level in the tank.
In practical terms, this is accomplished by means of a float that is attached to a moveable arm, the other end of which is in contact with a variable resistor. As the fuel level changes, the movable arm either rises or drops, which brings the contact point of the arm into contact with different parts of the variable resistor.
Thus, when the tank is empty, the resistor will generate the minimum reference voltage for that application because there is more resistant material for the current to pass through, which results in a lower voltage reaching the fuel gauge, giving an “Empty” reading. Conversely, when the tank is full, the resistance decreases, resulting in close to the maximum signal voltage being sent to the fuel gauge, thus producing a “Full” reading.
While the basic operating principles of fuel level sender units are much the same across all manufacturers, there are two notable exceptions to this rule. Ford and GM generally switch the electrical resistance around, meaning that on these makes the maximum signal voltage is generated when the tank is empty and vice versa : the minimum signal voltage is generated when the tank is full. The image below shows the typical construction of a fuel pump canister.
Note the fuel level sender unit that forms part of the canister. Be aware that not all level sender units are incorporated into the pump canister; on some applications the sender unit is mounted separately. Note: “Circuit Malfunction” indicates that there is a malfunction in the control circuit, as opposed to a fault in a sensor or other component.
With “Circuit Malfunction” codes, replacement of sensors and components in the affected circuit will almost never resolve the problem, since as the code suggests, the trouble is in the circuit . This distinction between “circuit” and “sensor/component” is a great help to anyone trying to diagnose a circuit malfunction code, since it narrows the list of possible causes down considerably.
The causes of “Circuit Malfunction” codes are much the same as those for “Open Circuits” i.e., broken wiring, poor connections across electrical connectors or previously repaired wiring, loss of ground that prevents current flow, blown fuses, defective relays, faulty switches, or any of a host of other issues and problems that prevents a flow of current through wiring. Issues like high/low/intermittent voltages can set a “Circuit Malfunction” code on some applications.
Moreover, “Circuit Malfunction” codes could also indicate a problem with negative current control / flow, as well as issues with failed or failing PCM’s (Powertrain Control Modules), although control module failure is a rare event.