For 1990-2009 cars

# Fuel Gauge Displays an Erratic or False Reading or No Start Condition after Vehicle is Shut Off with Low Fuel Level (Diagnose Fuel Gauge and Fuel Sender and/or Adjust/Replace Fuel Sender)

Subject: | Fuel Gauge Displays an Erratic or False Reading or No Start Condition after Vehicle is Shut Off with Low Fuel Level (Diagnose Fuel Gauge and Fuel Sender and/or Adjust/Replace Fuel Sender)

Models: | 2000-2005 Saturn L-Series Vehicles

Attention: | Technician

This bulletin has been revised with new measurements for "Height from Sump Bottom" column in the table. Please discard Corporate Bulletin Number 03-08-49-022A (Section 08 -- Body & Accessories).

### Condition

Some customers may comment on the fuel gauge displaying an erratic or false reading or that the vehicle will not start after it is shut off with a low fuel level.

### Cause

This condition may be caused by contamination of the fuel sender contacts or a misadjusted fuel sender float.

### Correction

Use the float measurement tables included in this bulletin to check for inaccurate sender resistance and adjustment of the fuel sender arm. To correct this condition, perform fuel gauge and sender diagnostics and, if necessary, replace/adjust fuel sender. Refer to service procedure in this bulletin.

### Service Procedure

Diagnostic Aids

• | Ensure that the fuel level is in the same range as the customer concern.

• | For intermittent diagnosis, refer to the "Testing for Intermittent and Poor Connections" section contained in this bulletin.

• | Refer to the "Fuel Level Specifications" tables contained in this bulletin to verify the correct fuel level sensor readings.

| The fuel level parameter is available on the scan tool in the powertrain fuel and emissions data list.

Test Description

The numbers below refer to the step number on the diagnostic table.

3. This step tests for a high resistance in the signal circuit and the low reference circuit of the fuel level sensor.

14. Diagnostic Trouble Codes (DTCs) will be set in the Engine Control Module/Powertrain Control Module (ECM/PCM) when you perform this diagnostic table.

Testing for Intermittent and Poor Connections

Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items:

• | Duplicate intermittent fault conditions by wiggling the harness, disconnecting and reconnecting connectors, pulling on the mechanical connection of a connector, pulling on the harness or wire in order to identify a separation/break inside the insulation.

• | Test for electrical intermittent opens, high resistances, short to ground and short to voltage on electrical circuits.

• | Wiring that is broken inside the insulation.

• | A poor connection between the male and female terminal at a connector.

• | A poor terminal to wire connection. Some conditions, which fall under this description are; poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area.

• | Wire insulation that is worn with wires visible. This causes an intermittent short as the bare wire area touches other wiring or parts of the vehicle.

Fuel Level Specifications

The values in the table are approximate values based on information obtained from properly operating vehicles. Actual results may vary slightly.

#### 2000 Model

Fuel Gauge Display | Resistance (Ohms) | Ohm Tolerance | Fuel Level (%) (4 CYL) | Fuel Level (Voltage) (V6) | Fuel Remaining/Fuel Level Parameters (Gallons) | Height from Sump Bottom to Float (mm)
--- | --- | --- | --- | --- | --- | ---
Empty | 232.4 - 250.0 | ± 1 | 0 - 10% | 2.61 - 2.65V | 0 - 1 | 0 - 12
1/4 | 179 | ± 2 | 30% | 2.29V | 4 | 54
1/2 | 142 | ± 4 | 50% | 2.00V | 7 | 80
3/4 | 84 | ± 2 | 79% | 1.39V | 10 | 111
Full | 20.0 - 37.5 | ± 1 | 90 - 98% | .43 - .61V | 13 - 14.4 | 135 - 150

#### 2001-2005 Models

Fuel Gauge Display | Resistance (Ohms) | Ohm Tolerance | Fuel Level (%) (4 CYL) | Fuel Level (Voltage) (V6) | Fuel Remaining/Fuel Level Parameters (Gallons) | Height from Sump Bottom to Float (mm)
--- | --- | --- | --- | --- | --- | ---
Empty | 235.0 - 250.0 | ± 1 | 0 - 10% | 2.61 - 2.65V | 0-1 | 0 - 8
1/4 | 166 | ± 2 | 27% | 2.18V | 4 | 46
1/2 | 123 | ± 2 | 51% | 1.84V | 8 | 82
3/4 | 86 | ± 2 | 71% | 1.45V | 11 | 110
Full | 20.0 - 43.1 | ± 1 | 90 - 98% | .43 - .76V | 14 - 16 | 139 - 157

#### Diagnostic Table

Fuel Gauge Inaccurate or Inoperative
Step | Action | Value(s) | Yes | No
1 | Perform the Instrument Cluster Diagnostic System Check by: Powering up scan tool and communicating with all controllers. Record all trouble codes and diagnose prior to proceeding. |  | Go to Step 2 |
2 |

1. Disconnect C406 Body to Fuel Tank inline connector located above Rear Suspension Support Assembly.
2. Connect the SA9205Z Decade Box between the signal circuit of the fuel level sensor (terminal H) and the low reference circuit of the fuel level sensor (terminal G) on the female terminal side.

Important: Verify the SA9205Z resistance settings with a Digital Multimeter Tester (DMM).

3. Vary the resistance on the SA9205Z from 20-250 (ohm)
4. Refer to the Fuel Level Specifications in this bulletin to convert from resistance to fuel gage display.

Does the IP fuel gage display the correct fuel level at various resistance settings?

--

Go to Step 4

Go to Step 3

3 |

1. Install a scan tool.
2. Turn ON the ignition, with the engine OFF.

Important: Verify the SA9205Z tester resistance settings with a DMM.

3. Vary the resistance on the SA9205Z tester from 20-250 (ohm)
4. Refer to the Fuel Level Specification in this bulletin to convert from resistance to fuel level percent.

Important: Turn OFF the ignition momentarily between the resistance settings in order to quickly update the scan tool display.

5. With the scan tool, observe the Fuel Level parameter in the Powertrain Fuel and Emissions data list.

Does the Fuel Level parameter in the Tech 2 display the correct fuel level at various resistance settings?

--

Go to Step 11

Go to Step 5

4 | Inspect for the following items:

• | A poor connection at the harness connector of the fuel level sensor. Refer to Testing for Intermittent and Poor Connections in this bulletin.

• | A high resistance in the signal circuit or the low reference circuit between the fuel level sensor and C406 Body to Fuel Tank inline connector.

• | A misaligned fuel level sender.

• | A deformed fuel tank.

Did you find and correct the condition?

--

Go to Step 14

Go to Step 7

5 | Test the signal circuit of the fuel level sensor for a high resistance. Did you find and correct the condition? | -- | Go to Step 14 | Go to Step 6
6 | Test the low reference circuit of the fuel level sensor for a high resistance. Did you find and correct the condition? | -- | Go to Step 14 | Go to Step 9
7 |

1. Remove the fuel pump module.
2. Inspect for the following items:

• | A stuck fuel level sensor (i.e. the fuel strainer interfering with the sender float arm).

• | A misaligned fuel level sender.

• | Foreign material in the fuel tank (i.e. ice).

| Did you find and correct the condition?

--

Go to Step 14

Go to Step 8

8 |

1. With the DMM, measure the resistance of the fuel level sensor while moving the float arm.
2. Observe both the analog and digital displays on the DMM.

Does the resistance change smoothly across the specified range?

20-250 (ohm)

Go to Diagnostic Aids and Fuel Level Specifications for Height measurements from Sump Bottom to Float and adjust.

Go to Step 14.

Go to Step 10

9 | Inspect for poor connections at the harness connector of the EMC/PCM. Refer to Testing for Intermittent and Poor Connections. Did you find and correct the condition? | -- | Go to Step 14 | Go to Step 13
10 | Replace the fuel level sensor. Refer to Fuel Level Sensor Replacement in the corresponding Service Manual. Did you complete the replacement? | -- | Go to Step 14 | --
11 | Replace the IPC. Refer to Instrument Panel Cluster (IPC) Replacement in the corresponding Service Manual. Did find and correct the condition? | -- | Go to Step 14 | Go to Step 12
12 | Important: Program the replacement BCM. Replace the BCM. Refer to the "Body Control Module (BCM) Replacement" procedure in the corresponding Service Manual. Did you complete the replacement? |  | Go to Step 14 | --
13 | Important: Program the replacement ECM/PCM. Replace the ECM/PCM. Refer to the "Engine Control Module (ECM) Replacement" procedure in the corresponding L81 Service Manual or to the "Powertrain Control Module (PCM) Replacement" procedure in the corresponding L61 Service Manual.

Did you complete the replacement?

--

Go to Step 14

--

14 |

1. Use the scan tool in order to clear the ECM/PCM DTCs.
2. Operate the system in order to verify the repair.

Did you correct the condition?

--

System OK

Go to Step 2

### Parts Information

Model Year | Part Number | Description
--- | --- | ---
2000 | 22681970 | Fuel Sender
2001-2005 | 22731878 | Fuel Sender

### Claim Information

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System for L1200 (Sender Assembly, Fuel [Tank Unit] - Replace or R&R).