Check Engine Light, Dead Fuel Gauge & Stall 2009 Dodge Charger 3. 5HO Diagnosis Part 1
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Date: 2026-03-07
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Comments and reviews: 20
2nickles647
A few years ago I went up northern Oklahoma where my grand daughter was living. Her Charger quit running, I talked her through the diagnostic process over the phone. Determined the fuel pump died. About two weeks later my daughter was going to Oklahoma too. I packed all of my tools, got two new fuel pumps and got on the train.
My grand daughter met me at Oklahoma City where I got dropped off. The next morning she went to work and I started working on replacing both pumps. It took me most of the day and as someone mentioned already. The left side pump needed to be reworked per the instructions. Got it done and the car fired up. I spent the night and she took me out to dinner.
The next am I packed my bags in her sister car she was driving. As I packed I noticed the rear tire was worn thru the thread and showing wires.
I found a tire joint and got two used tires and finally headed home. After a 12 hour drive I got home to New Mexico.
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A few years ago I went up northern Oklahoma where my grand daughter was living. Her Charger quit running, I talked her through the diagnostic process over the phone. Determined the fuel pump died. About two weeks later my daughter was going to Oklahoma too. I packed all of my tools, got two new fuel pumps and got on the train.
My grand daughter met me at Oklahoma City where I got dropped off. The next morning she went to work and I started working on replacing both pumps. It took me most of the day and as someone mentioned already. The left side pump needed to be reworked per the instructions. Got it done and the car fired up. I spent the night and she took me out to dinner.
The next am I packed my bags in her sister car she was driving. As I packed I noticed the rear tire was worn thru the thread and showing wires.
I found a tire joint and got two used tires and finally headed home. After a 12 hour drive I got home to New Mexico.
reply
autorepair
For the most part, the whole 'twin-tank' system seems fairly decent.
The only thing I'd change is to push the fuel from the LEFT side over to the RIGHT side (rather than the other way around.
More often than not, there's only ONE occupant in the vehicle (a. k. a. the loose nut behind the wheel) and thus there's 100-200 lb more on the drivers side (left in USA) than on the passengers side.
This 'imbalance' could be partially 'balanced' by trying to keep the tank on the OPPOSITE side of the vehicle more full.
Having said all that, this system would be IDEAL down here in NZ where we put that sole occupant on the RIGHT (a. k. a. 'correct') side of the vehicle. LOL
P. S. I lived in USA for 6 years around 2000. I _NEVER_ got completely used to walking out to the car, opening the door and then finding that some cheeky bugger had put the steering wheel on the WRONG side of the car.
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For the most part, the whole 'twin-tank' system seems fairly decent.
The only thing I'd change is to push the fuel from the LEFT side over to the RIGHT side (rather than the other way around.
More often than not, there's only ONE occupant in the vehicle (a. k. a. the loose nut behind the wheel) and thus there's 100-200 lb more on the drivers side (left in USA) than on the passengers side.
This 'imbalance' could be partially 'balanced' by trying to keep the tank on the OPPOSITE side of the vehicle more full.
Having said all that, this system would be IDEAL down here in NZ where we put that sole occupant on the RIGHT (a. k. a. 'correct') side of the vehicle. LOL
P. S. I lived in USA for 6 years around 2000. I _NEVER_ got completely used to walking out to the car, opening the door and then finding that some cheeky bugger had put the steering wheel on the WRONG side of the car.
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kd7cwg
The primary and secondary fuel pump modules are connected to each other inside the tank. Excess fuel is returned to the passenger side sender, then as that side fills up, it overflows back to the primary side. Programming reads the level of both sending units, and used both values to calculate the amount of fuel available. I've seen where the secondary sending unit has been replaced, and the pickup was not locked into the retainer at the bottom of the tank. It floted to the top. Fuel gage showed there was fuel, but because the secondary was floating on top of the fuel, it ran till the primary side of the tube was empty, because fuel was being returned to the secondary side, and couldn't be used.
That was fun to fix. Even with 3 pairs of nitrile gloves on, I got maybe a few minutes before the gas ate through them
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The primary and secondary fuel pump modules are connected to each other inside the tank. Excess fuel is returned to the passenger side sender, then as that side fills up, it overflows back to the primary side. Programming reads the level of both sending units, and used both values to calculate the amount of fuel available. I've seen where the secondary sending unit has been replaced, and the pickup was not locked into the retainer at the bottom of the tank. It floted to the top. Fuel gage showed there was fuel, but because the secondary was floating on top of the fuel, it ran till the primary side of the tube was empty, because fuel was being returned to the secondary side, and couldn't be used.
That was fun to fix. Even with 3 pairs of nitrile gloves on, I got maybe a few minutes before the gas ate through them
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99andrianmonk
Appreciate you taking us along on the whole process of learning about then diagnosing the issue with both the fuel sending units and the intake air valve. You could have just as easily decided that one or both gas tanks units needed to be replaced (shot the parts cannon dangerously with raw gas involved) and then throw in a new dashboard unit when the issue was not resolved vs taking the time to understand the system and diagnosis it as you did. You did what was best for your customer both from a cost of repair standpoint as well as having confidence the issue was actually resolved.
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Appreciate you taking us along on the whole process of learning about then diagnosing the issue with both the fuel sending units and the intake air valve. You could have just as easily decided that one or both gas tanks units needed to be replaced (shot the parts cannon dangerously with raw gas involved) and then throw in a new dashboard unit when the issue was not resolved vs taking the time to understand the system and diagnosis it as you did. You did what was best for your customer both from a cost of repair standpoint as well as having confidence the issue was actually resolved.
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HansJansen-q7l
This has happened a lot, that OEMs don't take into consideration that roads have a crown and vehicles mostly run on the right lane which means the fuel is higher on that side. A plain siphon will transfer fuel but the left side always runs out first. In this case they made sure that the right side would empty first, instead of drawing from the right side which would make more sense.
When I was still on the farm, occasionally a stink bug would alight on the upright muffler on the tractor and their feet would burn to the metal and you'd smell the result.
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This has happened a lot, that OEMs don't take into consideration that roads have a crown and vehicles mostly run on the right lane which means the fuel is higher on that side. A plain siphon will transfer fuel but the left side always runs out first. In this case they made sure that the right side would empty first, instead of drawing from the right side which would make more sense.
When I was still on the farm, occasionally a stink bug would alight on the upright muffler on the tractor and their feet would burn to the metal and you'd smell the result.
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autorepair
I had to rewire a 2006 Charger 3. 5. The funny thing is that both left and right side grounds for the pump are the same color, so it can be a pisser when messing with them. IIRC, they run to different areas in the car. I put 4 different sets of pumps in that car as the Delphi brand had dead pumps out of the box, and the Carter made one worked. My Mercedes-AMG is made similar to that style of tank, so I was prepared when having to deal with it as it's the same theory of operation.
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I had to rewire a 2006 Charger 3. 5. The funny thing is that both left and right side grounds for the pump are the same color, so it can be a pisser when messing with them. IIRC, they run to different areas in the car. I put 4 different sets of pumps in that car as the Delphi brand had dead pumps out of the box, and the Carter made one worked. My Mercedes-AMG is made similar to that style of tank, so I was prepared when having to deal with it as it's the same theory of operation.
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sharg0
For the functionality of a venturi and associated low pressure: Compare it to an old carburator, the air passes the venturi and creates a low pressure that pulls in the fuel from the reservoir. This gets even more efficient when the mediums are liquid/liquid instead of gas/liquid. (This principle is also used in some deep drilled wells were you have a pump on the surface that actually pushes water down in one (smaller) pipe to then get a significant higher volume back up)
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For the functionality of a venturi and associated low pressure: Compare it to an old carburator, the air passes the venturi and creates a low pressure that pulls in the fuel from the reservoir. This gets even more efficient when the mediums are liquid/liquid instead of gas/liquid. (This principle is also used in some deep drilled wells were you have a pump on the surface that actually pushes water down in one (smaller) pipe to then get a significant higher volume back up)
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williamrarick6272
12 volt circuits, (open circuit voltage) Sensors are in the neighborohood of 60 ohms on one end to 350 ohms on the other. (can't remember exactly what they are as it's been years since I've diagnosed one) Yes you are correct on the connector pin out. Make sure you have ground then check OC voltage, the more current model years use 5 volt circuits but the same principle applies (as stated previously) Check voltage at the MIC and make sure no short on circuit.
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12 volt circuits, (open circuit voltage) Sensors are in the neighborohood of 60 ohms on one end to 350 ohms on the other. (can't remember exactly what they are as it's been years since I've diagnosed one) Yes you are correct on the connector pin out. Make sure you have ground then check OC voltage, the more current model years use 5 volt circuits but the same principle applies (as stated previously) Check voltage at the MIC and make sure no short on circuit.
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randybeard6040
When will these Vehicle Company Engineers Quit Building Over-Engineered Vehicles, nothing is Simple to Work on these Days, I am a Old Fart of the 60's when Cars would Run just as good as ones today plus last much Longer and were Easy to Repair. From what I hear, Mechanic Techs are in High Demand All Over America. It appears they cannot make enough money working on these Complicated Vehicles.
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When will these Vehicle Company Engineers Quit Building Over-Engineered Vehicles, nothing is Simple to Work on these Days, I am a Old Fart of the 60's when Cars would Run just as good as ones today plus last much Longer and were Easy to Repair. From what I hear, Mechanic Techs are in High Demand All Over America. It appears they cannot make enough money working on these Complicated Vehicles.
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sergiojacas8268
Had this engine. I replaced that little runner motor, the code went away for a week, and produced the code again. But what I figured is the runners inside the intake manifold get gummed up and they stick. So replacing the manifold fixed it. According to forum you can't clean to remove the gummed runners, don't know if that is true, as I just replaced the whole intake manifold. Good luck.
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Had this engine. I replaced that little runner motor, the code went away for a week, and produced the code again. But what I figured is the runners inside the intake manifold get gummed up and they stick. So replacing the manifold fixed it. According to forum you can't clean to remove the gummed runners, don't know if that is true, as I just replaced the whole intake manifold. Good luck.
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williamrarick6272
You here the pump run but does it sound as if under load Different sound. The fuel guage is an average of the 2 fuel level sensors, and you do have one sensor sitting at 0 v meaning shorted. Less than. 5 and more than 4. 5 volts are diagnostic area's for shorts to ground, shorts to voltage and open. That being said, normal voltages should read between 0. 7 and 4. 3 volts.
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You here the pump run but does it sound as if under load Different sound. The fuel guage is an average of the 2 fuel level sensors, and you do have one sensor sitting at 0 v meaning shorted. Less than. 5 and more than 4. 5 volts are diagnostic area's for shorts to ground, shorts to voltage and open. That being said, normal voltages should read between 0. 7 and 4. 3 volts.
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autorepair
Spending more time on something you really have not work on is never waste of time. It's called learning on the job. With all the different brands of cars Eric works he does the best I have seen. You can tell when it's something Eric has not work on he gets excited to find the problem. Eric is like a hunting dog finding something new. lol
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Spending more time on something you really have not work on is never waste of time. It's called learning on the job. With all the different brands of cars Eric works he does the best I have seen. You can tell when it's something Eric has not work on he gets excited to find the problem. Eric is like a hunting dog finding something new. lol
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3dphillo396
Think about how a deep well pump works. The pump pushes water down the well, goes through a venturi (jet) and pulls water from the well, ADDING more water to the return line. The pump then pushes the extra water to the rest of the cold water system in your home.
Maybe this system works the same way but with fuel. Cool idea though.
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Think about how a deep well pump works. The pump pushes water down the well, goes through a venturi (jet) and pulls water from the well, ADDING more water to the return line. The pump then pushes the extra water to the rest of the cold water system in your home.
Maybe this system works the same way but with fuel. Cool idea though.
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glennoliver1871
I have learned so much from your videos. I want to caution you about the repeated exposure to petrochemicals on your bare hands (gasoline) and the brake cleaner vapors. The years of daily exposure is cumulative on your body. I know it’s your business but properly protecting yourself is very important to your health.
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I have learned so much from your videos. I want to caution you about the repeated exposure to petrochemicals on your bare hands (gasoline) and the brake cleaner vapors. The years of daily exposure is cumulative on your body. I know it’s your business but properly protecting yourself is very important to your health.
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s. j. 5850
The engineers just had to have a two-sided tank instead of the normal one tank system that we have been using for decades. I guess they got bored working on the same 4 wheel people movers so they get creative & come up with the two in one. Double the fun when something goes wrong & maybe even double the price to repair!
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The engineers just had to have a two-sided tank instead of the normal one tank system that we have been using for decades. I guess they got bored working on the same 4 wheel people movers so they get creative & come up with the two in one. Double the fun when something goes wrong & maybe even double the price to repair!
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Cyb3rn3tiX
Mrs O gave you her cold lol, also my 2002 Volvo D5 has this fuel tank setup and i also have fueling issues sometimes tank says 1/2 full then sometimes 3/4 full saddle tanks are the worse unless a line is fed between the two tanks with out the secondary pump to equal it out nice vid now to check the volvo
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Mrs O gave you her cold lol, also my 2002 Volvo D5 has this fuel tank setup and i also have fueling issues sometimes tank says 1/2 full then sometimes 3/4 full saddle tanks are the worse unless a line is fed between the two tanks with out the secondary pump to equal it out nice vid now to check the volvo
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SmittySmithsonite
Do engineers try to create the most complex system out of a competition amongst themselves I remember when the tank consisted of a float. and a HOSE! Boy do I miss those days! I think that's what that car needs - a carburetor and some points! Then all these problems go away instantly.
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Do engineers try to create the most complex system out of a competition amongst themselves I remember when the tank consisted of a float. and a HOSE! Boy do I miss those days! I think that's what that car needs - a carburetor and some points! Then all these problems go away instantly.
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farmermiyagi1338
Goooood evenin kids! Mr O. Dinner theater! After the valve covers on that Wrangler I'm down to watching someone else do the work. I had to put hubs and fix the rear brakes on a Sierra just to purge the Jeep frustration out of my blood. Goddamighty who designed that engine! o. 0
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Goooood evenin kids! Mr O. Dinner theater! After the valve covers on that Wrangler I'm down to watching someone else do the work. I had to put hubs and fix the rear brakes on a Sierra just to purge the Jeep frustration out of my blood. Goddamighty who designed that engine! o. 0
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LarryMartin-k5c
As I was watching you at the end of this video I could see on the wall behind you the light that say check engine I wonder if someone makes a light like that but says money light instead of check engine lol would be cool to have something like that on the wall of a mechanic shop lol
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As I was watching you at the end of this video I could see on the wall behind you the light that say check engine I wonder if someone makes a light like that but says money light instead of check engine lol would be cool to have something like that on the wall of a mechanic shop lol
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bigragu6828
but why did the fuel overflow the left side of the tank you didnt open the right side so its not clear if both saddles were overflowing. shouldnt it have crossed the bridge and equal out again, maybe it did and both sides were overflowing. great process to figure it out.
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but why did the fuel overflow the left side of the tank you didnt open the right side so its not clear if both saddles were overflowing. shouldnt it have crossed the bridge and equal out again, maybe it did and both sides were overflowing. great process to figure it out.
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