For 1990-2009 cars

# VEHICLE RUNS OUT OF FUEL WITH 1/8 TO 1/4 OF FUEL

#### SUBJECT: Vehicle Runs Out of Fuel with 1/8 to 1/4 of Fuel Indicated on the Fuel Gage (Check for Plugged Fuel Tank and EVAP Canister Vent) ------------------------------------------------------------------

#### MODELS AFFECTED: ---------------- 1991-1997 Saturns

#### CONDITION:

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The vehicle may quit running or run out of gas with the fuel gage showing 1/8 to 1/4 tank of fuel. An initial inspection of the fuel tank may show that the fuel tank is collapsed in the center of the fuel tank.

#### CAUSE:

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This condition may be caused by a plugged vent at the EVAP canister. During certain driving conditions, fuel vapors in the EVAP canister are drawn into the intake manifold by engine vacuum. When the vapors are drawn out of the EVAP canister, air is drawn into the EVAP canister vent to allow the fuel vapors to be purged from the EVAP canister. If the vent line becomes plugged and the fuel level is low, the vacuum being applied to the EVAP canister is then applied through the fuel tank vapors pipe from the EVAP canister to the fuel tank. This vacuum may be enough to collapse the center of the fuel tank. When the center of the fuel tank collapses upward, it causes the fuel sending unit to be mispositioned, causing a false fuel gage reading.

#### CORRECTION:

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Refer to the following procedure to inspect the EVAP canister vent and vent hose.

#### PROCEDURES

#### CAUTION:

DO NOT ALLOW SMOKING OR THE USE OF OPEN FLAMES IN THE AREA WHERE WORK ON THE FUEL SYSTEM IS TAKING PLACE. ANYTIME THE FUEL SYSTEM IS BEING WORKED ON, DISCONNECT THE NEGATIVE BATTERY CABLE, EXCEPT FOR THOSE TESTS WHERE BATTERY VOLTAGE IS REQUIRED.

1. Disconnect negative battery cable.

2. Remove the EVAP canister vent hose or dust cap (application varies across the within model years), and inspect for a restriction in the hose or the canister vent port. (The most common restriction is spiders that nest in this area.)

#### CAUTION:

TO PREVENT POSSIBLE EYE INJURIES, SAFETY GLASSES MUST BE WORN WHEN PERFORMING THE FOLLOWING PROCEDURE.

3. If no restriction is visually evident in the vent hose or the EVAP canister vent port, blow shop air through the disconnected vent hose to clear the vent hose of any restrictions. If the vent is clear, then the restriction is internal to the EVAP canister and the EVAP canister must be replaced. (Refer to appropriate year "Fuel/Air Intake/Exhaust Service Manual" for proper EVAP canister removal and installation procedures.)

4. After the vent or hose is cleaned, or the EVAP canister is replaced, inspect the fuel tank. If the fuel tank is still collapsed, replace the fuel tank. (Refer to appropriate year "Fuel/Air Intake/ Exhaust Service Manual" for proper fuel tank removal and installation procedures.)

5. Connect negative battery cable.

#### PARTS REQUIREMENTS:

Model P/N Description Year Usage

21007024 Canister Kit-EVAP Emis 91-94 All 21007306 Canister Kit - EVAP Emis 95-97 All

#### NOTE: Pipe - EVAP canister vent not included in kit (21007306), and is not required.

21006833 Tank Asm -Fuel 91-97 All

#### NOTE: 1991 - 92 vehicles require that the fuel tank vent pipe assembly be replaced when replacing the original fueltank.

21006834 Pipe Asm- F/Tank Fill Vent 91-92 A35, A69 21006835 Pipe Asm- F/Tank Fill Vent 91-92 A27

#### CLAIM INFORMATION:

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System using the appropriate Electronic Labor Time Guide and Labor Operation Code L0620 Replace Fuel Vapor Canister) and/or L1260 (Replace Fuel Tank).

General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.