Fuel Level Sensor
The fuel gauge sending unit or fuel level sensor is attached to the side of the fuel pump module. See Fig 1 . The sending unit consists of a float, an arm and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD-II emission requirements. The other 2 wires are used for electric fuel pump operation. For fuel gauge operation, a constant current 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 Powertrain Control Module (PCM). The resistor track is used to vary the voltage 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 PCM through the sensor return circuit. Output voltages will vary from about .6 volt at FULL, to about 7.0 volts at EMPTY. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired, not multiplexed. After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multiplex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. For OBD-II emission monitor requirement, the PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD-II system from recording/setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than about 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than about 85 percent of its rated capacity.