Saturn Coupes/Sedans/Wagons 1991-1998 Repair Guide

Fuel Level Sender

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OPERATION



This sending unit is a rheostat type, meaning that the resistance (or signal) changes according to the fuel level inside the tank. On some models, the Powertrain Control Module (PCM) monitors the resistance of the fuel level sending unit to calculate the amount of fuel in the tank, and supplies voltage to the sending unit through a network of resistors and a return to ground. On other models, the PCM is not part of the circuit.

TESTING



See Figures 1, 2, 3 and 4

The fuel level sending unit can be most accurately diagnosed while still in the vehicle with a full or empty fuel tank.

  1. Be sure that the ignition is turned OFF . Open the trunk lid or liftgate and turn back the carpet against the left side.
  2.  
  3. Unplug the in-line fuel connector.
  4.  
  5. With the ohmmeter probes placed at connector pins B and C of the sending unit side connector, check the resistance and compare it to the figures in the appropriate chart.
  6.  
  7. If the resistance reading(s) do not coincide with the figures in the chart, replace the fuel level sending unit.
  8.  
  9. Attach the in-line fuel connector and reposition the carpet.
  10.  



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Fig. Fig. 1: Location of the in-line fuel connector



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Fig. Fig. 2: Schematic for the fuel level sending unit



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Fig. Fig. 3: Fuel level sending unit resistance chart for 1991-96 models



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Fig. Fig. 4: Fuel level sending unit resistance chart for 1997-98 models

REMOVAL & INSTALLATION



The fuel level sending unit is mounted on the fuel pump module assembly, which is located in the fuel tank. If the sending unit requires replacement, the fuel tank must be removed. refer to Fuel System for Fuel Tank removal and installation.

 
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