Fuel Level Sending Unit / Sensor: Operation

WARNING: This page is about a different car, the 2004 Dodge Pickup and 2004 Dodge Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

The fuel tank module on diesel powered models has 2 different circuits (wires). Two of these circuits are used at the fuel gauge sending unit for fuel gauge operation. The diesel engine does not have a fuel tank module mounted electric fuel pump. The electric fuel pump (fuel transfer pump) is mounted to the engine.

For Fuel Gauge Operation: A constant input voltage source of about 12 volts (battery voltage) is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Engine Control Module (ECM).NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel tank module electrical connector unplugged). With the connectors plugged, output voltages will vary from about .6 volts at FULL, to about 7.0 volts at EMPTY. The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the ECM through the sensor return circuit.

Both of the electrical circuits between the fuel gauge sending unit and the ECM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the ECM, the ECM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. Refer to INSTRUMENT CLUSTER for additional information.