Instruments - Fuel Gage Reads Incorrectly
NO.:92-T-29
DATE:
June, 1992
GROUP:
Engine
CORP. NO.:
288301
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."
^ If resistance is above 300 ohms, inspect wiring and connections and repair as necessary.
^ 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.
^ 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.
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.
^ 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:
33.0 mm (1.30 in.) minimum
38.0 mm (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)