Fuel Gauge Displays An Erratic Or False Reading Or No Start Condition After Vehicle Is Shut Off With Low Fuel Level (03-08-49-022A)
Publication date: 2004-09-24Reference number: 03-08-49-022A
Supersedes refnos: 03-08-49-022
FUEL GAUGE DISPLAYS AN ERRATIC OR FALSE READING OR NO START CONDITION AFTER VEHICLE IS SHUT OFF WITH LOW FUEL LEVEL
TECHNICAL SERVICE BULLETIN
Reference Number(s): 03-08-49-022B, Date of Issue:
September 24, 2004
Superceded Bulletin(s): 03-08-49-022A
| SATURN: | 2000-2005 Saturn L-Series Vehicles |
| SECTION: | 08 - Body & Accessories |
NOTE:
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 included 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 contained 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
The numbers below refer to the step number on the diagnostic table )FUEL GAUGE INACCURATE OR INOPERATIVE DIAGNOSTIC TABLE ).
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.
2000 MODEL
| Fuel Gauge Display | Resistance (Ohms) | Ohm Tolerance | Fuel Level (%) (4 CYL) | Fuel Level (Voltage) (V6) | Fuel Remaining/Fuel Level Parameters (Gallons) | Height from Sump Bottom to Float (mm) |
|---|---|---|---|---|---|---|
| Empty | 232.4 - 250.0 | +/- 1 | 0 - 10% | 2.61 - 2.65V | 0 - 1 | 0 - 12 |
| 1/4 | 179 | +/- 2 | 30% | 2.29V | 4 | 54 |
| 1/2 | 142 | +/- 4 | 50% | 2.00V | 7 | 80 |
| 3/4 | 84 | +/- 2 | 79% | 1.39V | 10 | 111 |
| Full | 20.0 - 37.5 | +/- 1 | 90 - 98% | .43 - .61V | 13 - 14.4 | 135 - 150 |
2001-2005 MODELS
| Fuel Gauge Display | Resistance (Ohms) | Ohm Tolerance | Fuel Level (%) (4 CYL) | Fuel Level (Voltage) (V6) | Fuel Remaining/Fuel Level Parameters (Gallons) | Height from Sump Bottom to Float (mm) |
|---|---|---|---|---|---|---|
| Empty | 235.0 - 250.0 | +/- 1 | 0 - 10% | 2.61 - 2.65V | 0-1 | 0 - 8 |
| 1/4 | 166 | +/- 2 | 27% | 2.18V | 4 | 46 |
| 1/2 | 123 | +/- 2 | 51% | 1.84V | 8 | 82 |
| 3/4 | 86 | +/- 2 | 71% | 1.45V | 11 | 110 |
| Full | 20.0 - 43.1 | +/- 1 | 90 - 98% | .43 - .76V | 14 - 16 | 139 - 157 |
FUEL GAUGE INACCURATE OR INOPERATIVE DIAGNOSTIC
| Step | Action | Value(s) | Yes | No |
|---|---|---|---|---|
| 1 | Perform the Instrument Cluster Diagnostic System Check by: Powering up scan tool and communicating with all controllers. Record all trouble codes and diagnose prior to proceeding. | -- | Go to Step 2 | -- |
| 2 |
IMPORTANT:
Verify the SA9205Z resistance settings with a Digital Multimeter Tester (DMM).
|
-- | Go to Step 4 | Go to Step 3 |
| 3 |
IMPORTANT:
Verify the SA9205Z tester resistance settings with a DMM.
IMPORTANT:
Turn OFF the ignition momentarily between the resistance settings in order to quickly update the scan tool display.
Does the Fuel Level parameter in the Tech 2 display the correct fuel level at various resistance settings? |
-- | Go to Step 11 | Go to Step 5 |
| 4 | Inspect for the following items: A poor connection at the harness connector of the fuel level sensor. Refer to Testing for Intermittent and Poor Connections in this bulletin. A high resistance in the signal circuit or the low reference circuit between the fuel level sensor and C406 Body to Fuel Tank inline connector. A misaligned fuel level sender. A deformed fuel tank. Did you find and correct the condition? |
-- | Go to Step 14 | Go to Step 7 |
| 5 | Test the signal circuit of the fuel level sensor for a high resistance. Did you find and correct the condition? |
-- | Go to Step 14 | Go to Step 6 |
| 6 | Test the low reference circuit of the fuel level sensor for a high resistance. Did you find and correct the condition? |
-- | Go to Step 14 | Go to Step 9 |
| 7 |
|
-- | Go to Step 14 | Go to Step 8 |
| 8 |
Does the resistance change smoothly across the specified range? |
20-250 (ohm) | Go to Step 14. | Go to Step 10 |
| 9 | Inspect for poor connections at the harness connector of the EMC/PCM. Refer to Testing for Intermittent and Poor Connections. Did you find and correct the condition? |
-- | Go to Step 14 | Go to Step 13 |
| 10 | Replace the fuel level sensor. Refer to Fuel Level Sensor Replacement in the corresponding Service Manual. Did you complete the replacement? |
-- | Go to Step 14 | -- |
| 11 | Replace the IPC. Refer to Instrument Panel Cluster (IPC) Replacement in the corresponding Service Manual. Did find and correct the condition? |
-- | Go to Step 14 | Go to Step 12 |
| 12 | Important Program the replacement BCM. Replace the BCM. Refer to the ""Body Control Module (BCM) Replacement"" procedure in the corresponding Service Manual. Did you complete the replacement? |
-- | Go to Step 14 | -- |
| 13 | Important Program the replacement ECM/PCM. Replace the ECM/PCM. Refer to the ""Engine Control Module (ECM) Replacement"" procedure in the corresponding L81 Service Manual or to the ""Powertrain Control Module (PCM) Replacement"" procedure in the corresponding L61 Service Manual. Did you complete the replacement? |
-- | Go to Step 14 | -- |
| 14 |
Did you correct the condition? |
-- | System OK | Go to Step 2 |
PARTS INFORMATION
PARTS INFORMATION
| Model Year | Part Number | Description |
|---|---|---|
| 2000 | 22681970 | Fuel Sender |
| 2001-2005 | 22731878 | Fuel Sender |
WARRANTY 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).