FUEL GAGE READS LOW FOR FUEL REMAINING-REPLACE SENDING UNIT. Saturn Saturn 1991

For 1990-2009 cars

# FUEL GAGE READS LOW FOR FUEL REMAINING-REPLACE SENDING UNIT

#### SUBJECT: Fuel Gage Reads Low for Fuel Remaining (Replace Fuel Gage or Sending Unit) All 1991 Satums-VIN No. from 109087 and Below.

CONDITION: Some customers may comment that their fuel gage reads low for the amount of fuel remaining in the tank.

CAUSE: Some fuel sending units may have a heavy float ball.

#### CORRECTIVE ACTION:

Verify fuel gage operation. If gage is operating properly, replace fuel sending unit.

#### NOTE: The September 1990 "Body Service Manual" does not have Instrument Cluster removal and installation procedures. Please photo copy the Instrument Cluster removal and installation procedures that are part of this bulletin, insert them into the "Body Service Manual" and use for removal and installation of the instrument cluster.

#### PROCEDURE:

---------- 1. Verify that the fuel gage is not stuck on empty by following Steps 1a through 1d.

a. Jumper pins B and C on the male side of the in-line connector located in the rear compartment.

b. Observe the fuel gage, with pins B and C connected together with the jumper wire. The needle should be at, or past the FULL mark.

c. If the fuel gage needle is not at, or past the FULL mark, inspect all connections from this connector to the instrument panel cluster.

d. If connections are good, and gage does not read full, replace the instrument panel cluster according to the "Instrument Cluster Assembly" removal and installation procedures in this bulletin.

e. If the fuel gage is not stuck on empty, replace the fuel sender assembly according to the procedures in the "Fuel Delivery System" section of the September 1990 "Fuel/Air Intake/Exhaust" Service Manual.

#### INSTRUMENT CLUSTER ASSEMBLY

REMOVAL

1. Disconnect negative battery terminal.

2. Remove upper trim panel screw caps by carefully prying with a small flat-head screwdriver.

3. Remove upper trim panel screws.

4. Lift upper trim panel to disengage clips at rear edge.

5. Pull panel rearward out of the clips at the bottom of the windshield.

6. Remove upper trim panel.

#### NOTICE: Start at the bottom clips and work up to the top clips. Do not use any instrument that may damage the trim panel.

7. Carefully remove center air outlet/trim panel by pulling outward at clip location.

8. Open the glove box.

9. Remove screws and pull cluster trim panel rearward to disengage retainers.

10. Remove connector position assurance (CPA) devices and disconnect the electrical connectors from the instrument panel lighting and rear window defogger switches.

11. Remove the cluster trim panel.

12. Remove screws and pull instrument cluster assembly out enough to disconnect electrical connectors.

13. Disconnect electrical connectors, by depressing the retainer tabs, and remove the instrument cluster assembly.

INSTALLATION

1. Connect electrical connectors on instrument cluster assembly.

#### IMPORTANT: Make sure electrical connectors for instrument panel lighting and rear window defogger switches are in place.

2. Install instrument cluster assembly and screws.

3. Position cluster trim panel to instrument panel.

4. Connect electrical connectors on instrument panel lighting and rear window defogger switches and install CPA devices to electrical connectors.

5. Install cluster trim panel into retainers.

6. Install and tighten screws.

7. Install center air outlet/trim panel, by pushing in at clip locations.

8. Install upper trim panel by inserting it into clips at windshield and snapping rear of panel into place.

9. Install upper trim panel screws and screw caps.

10. Connect negative battery terminal.

11. Set clock to proper time.

#### PARTS REQUIREMENTS:

Model Codes Usage ------------------------------------------------------------- 21006333 Sender Asm-Fuel 21021209 Cluster Asm-Inst B69 LKO&MP2&J41 21021210 Cluster Asm-Inst B69 LKO&JL9/MP6 21021211 Cluster Asm-Inst B27,D69

#### CLAIM INFORMATION:

To receive credit for this repair submit a warranty claim through the Saturn Dealer System using one of the labor operations listed below:

Case Labor Type Description Code Time ---- --------------------------- ---- --------- Gage and/or "O" Ring VW Fuel (Tank Unit) - Replace L1200 1.2 hrs Instrument Cluster VW Replace N4180 0.6 hrs

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.