Instruments - Erratic/False Fuel Gauge Readings
Bulletin No.: 03-08-49-022BDate: September 24, 2004
TECHNICAL
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
Supercede:
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 shown 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 shown 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
T�:
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The numbers below refer to the step number on the diagnostic table shown.
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.
Parts Information
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).
Disclaimer