I/P FUEL GAGE READS INCORRECT DIAGNOSE/REPLACE FUEL SENDER. Saturn Saturn 1991

For 1990-2009 cars

# I/P FUEL GAGE READS INCORRECT DIAGNOSE/REPLACE FUEL SENDER

#### SUBJECT: Instrument Panel Fuel Gage May Read Incorrectly (Diagnose/Replace Fuel Sender Float)

#### MODELS AFFECTED:

All 1991 and 1992 Saturns

#### CONDITION:

The I/P fuel gage may read incorrectly low when compared to the amount of fuel known to be in the tank. This condition may be noticeable after the customer fills up the tank and the gage does not read full or when the gage reads empty and less fuel can be added to the fuel tank than expected.

#### CAUSE:

The float attached to the fuel sender assembly may fill with fuel not allowing it to float on the top of the fuel as designed, but to sink into the fuel giving an incorrect reading to the I/P fuel gage.

CORRECTIVE ACTION: Check instrument panel gage calibration by using procedures located in the "Electrical Power Distribution Service Manual." If readings are incorrect, repair as required.

If instrument panel gage reads correctly, measure resistance from fuel sender assembly according to procedures under "Fuel Gage Tank Unit Calibration and Electrical Circuit Test" located in the "Diagnostics and Test Procedures" section of the "Fuel/Air Intake/Exhaust Service Manual."

o If resistance is above 300 ohms, inspect wiring and connections and repair as necessary.

o If problem is not found or resistance is less than 300 ohms, visually inspect fuel sender float for cracks and fuel intrusion. If there is evidence of fuel in the float, replace the float according to the procedures in this bulletin.

o If there is no evidence of fuel in the float, replace fuel sender assembly with the service replacement part.

#### PROCEDURES:

1. Refer to "Fuel Pump Module Removal" procedures in the "Fuel Tank, Pump, Filter Lines and Canister" section of the "Fuel/Air Intake/Exhaust Service Manual" and remove the fuel pump assembly.

2. Check the float for evidence of fuel intrusion.

o If there is no fuel inside the float, replace the fuel sender assembly. Refer to "Fuel Pump Module Installation" procedures in the "Fuel Tank, Pump, Filter Lines and Canister" section of the "Fuel/Air Intake/Exhaust Service Manual" and remove the fuel sender assembly.

o If there is fuel inside the float, proceed to Step 3 of these procedures.

#### NOTICE: When removing the float from the hook at the end of the fuel sender assembly's wire arm, use extreme care not to bend the wire arm.

3. Remove the white plastic or brass float with a screwdriver. Insert the screwdriver between the sender arm and float, then carefully pry the float out of the wire hook.

#### NOTICE: If the float is dented when installing it into the hook at the end of the fuel sender assembly's wire arm, it must be replaced.

4. Insert the new float (P/N 21007036) in the fuel sender assembly's wire arm retaining hook by carefully pinching the float into place.

5. Check the float's position relative to the bottom of the sender unit using a square. Measure the distance between the bottom of the fuel sender assembly and float. If the float position is not correct, use two pliers and carefully bend the fuel sender assembly's arm at the 90 degree bend directly below the fuel sender assembly. Always double check the distance between the bottom of the fuel sender assembly and float, after the fuel sender assembly's arm has been bent.

#### Service Limits:

33.Omm (1.30 in.) minimum 38.Omm (1.50 in.) maximum

6. Refer to "Fuel Pump Module Installation" procedures in the "Fuel Tank, Pump, Filter Lines and Canister" section of the "Fuel/Air Intake/Exhaust Service Manual" and carefully install the fuel pump assembly.

7. Prime the fuel system.

a. Cycle the ignition On for five seconds, then Off for ten seconds.

b. Repeat Step 7a twice.

c. Crank engine until it starts (maximum motor cranking time is 20 seconds).

d. If engine does not start, repeat Steps 7a through 7c.

#### IMPORTANT: It may be necessary to turn the ignition switch On and Off several times to adequately prime the fuel system.

8. Run the engine and check for fuel leaks.

PARTS REQUIREMENTS: 21007036 Float -Fuel Sender Assembly 21010288 Seal-Fuel Sender (O Ring) 21006949 Sender Assembly-Fuel

CLAIM INFORMATION: To receive credit for this repair, submit a claim through the Saturn Dealer System as follows: Labor Case Operation Type Description Code Time ---- ----------- --------- ---- VW Sender, Float and/or O-Ring, L1200 1.5 hrs Fuel (Tank Unit) - Replace (Base time includes performing a fuel sender assembly resistance check)

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.