Fuel Level Sender

WARNING: This page is about a different car, the 2013 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.

The fuel level sender is mounted to the fuel pump assembly or the fuel level sensor. The fuel level sender is a dual sweep potentiometer style resistor connected to a float mechanism. The dual sweep design provides a second resistance measurement that reduces the intermittent loss of data due to corrosion between the resistor wires and the sweep arm. As the fuel level changes, the float rises or falls with the fuel level moving the sweep arm across the resistor wires. This movement either increases or decreases the resistance through the unit. The fuel level sensor resistance ranges from 180 ohms ± 4 ohms at empty (E) to 10 ohms ± 2 ohms at full (F). When the fuel level is low, the fuel level sensor resistance is high. When the fuel level is high, the fuel level sensor resistance is low.

Both the fuel pump assembly and fuel level sensor are hardwired to the IPC through separate signal and return circuits. The fuel level return circuits are grounded internally in the IPC . The IPC provides a battery reference voltage on the fuel level signal circuit. As the fuel level changes, the change in resistance raises or lowers the fuel level signal voltage depending on the resistance of the fuel level sender.