I have been getting an intermittent CEL along with a fuel gauge fluctuating below 1/4 tank (goes from 1/4 to below empty cycle every 5 minutes or so). Last night Scott at Troncalli (thanks!) read it as P0463 - Fuel Level Sensor Circuit High Input. Seems the fix is to replace the 2 fuel level sensors. One is attached to the fuel pump. My questions are: 1. How hard is this to do in a wagon ('02)? 1. The sensor attached to the pump - can it be replaced by itself? The service manual indicated it can, but Scott thought it was easiest to replace the whole pump. I think I saw the pump price on subarugenuineparts and it was almost $300. Does that sound right?
the right side is a complete assembly, its not cheap. the left side is cheaper...as its smaller, but its likely to be $100 or more. Replacing both units will solve the problem.
Brian at Troncalli said he had a P/N for only the sensor on the pump side and can order only it. I have done that and will pick it up tomorrow. I am going to replace one at a time (maybe I can get lucky and replace the bad one first). I have read the shop manual about removing the fuel pump. Is it as easy as it looks? The manual talks about draining the tank. Is this necessary? Are the hoses tight on the pump? If so, any tricks to remove / install them? I usually use a hair dryer to soften the hose, but may be a little apprehensive to doing this near the tank. (Edit - I see that the hoses have clamps. That means once the clamp is off it shouldn't be too bad - right?)
The reason for tank drain is to not get gas spilled from the pump assy. inside the car. Just be careful and use some old towels and stuff for little drops that may spill. If I remember right the lines on the top of the tank were quich disconnects, most cars are. aiadid my pump a few months ago and it took less than 30 minutes. Good luck!
After replacing the first sensor (on fuel pump) CEL was gone, but gauge was still not reading right below 1/3 tank. I replaced the other sensor and all seems good now. I think I have about 3 gallons left and needle is still just above empty.