Fuel Gauge Displays a False Low Reading or is Stuck on Empty (Perform Resistance Check on Fuel Level Senders, and If Necessary, Replace Primary and Secondary Fuel Level Senders)

This bulletin is being revised due to a change in Fuel Level Senders and the Models Affected. Please discard bulletin 02-T-38 (Corporate Bulletin Number 02-06-04-021, Section 06 - Engine).

Some customers may comment that the fuel gauge is displaying a false low reading or stuck on empty. This condition may be intermittent. A DTC P0461 - Fuel Level Sensor Performance may also be set in ECM memory.

This condition may be caused by contamination of the fuel level senders.

The material used in the fuel sender wiper arm contacts has changed to reduce sensitivity to corrosion in certain fuels. To correct this condition, perform a resistance check throughout the entire range of motion on primary and secondary fuel level senders, and if necessary, replace senders. Refer to service procedure in this bulletin.

Important: It is not necessary to remove or separate the Rear Drive Module (RDM). Sufficient clearance is gained by removing the propeller shaft and propeller shaft guard.

1. Remove fuel tank. Refer to "Fuel Tank" removal procedure in the fuel system section of the 2002-2003 VUE Engine Service Manual.
2. Remove primary and secondary fuel pump modules. Refer to "Primary and Secondary Fuel Pump Module" removal procedure in the fuel system section of the 2002-2003 VUE Engine Service Manual.
3. Using a DVOM, check the resistance of both primary and secondary fuel level senders. The resistance should be close to the readings in the table below, and should change evenly when moving float arm through range of motion.

•

If resistance changes are erratic while sweeping float arm or readings are significantly different than in the table below, it will be necessary to replace both primary and secondary fuel level senders with new senders identified in this bulletin. Refer to "Fuel Level Sender Unit and Float" removal and installation procedures in the fuel system section of the 2002-2003 VUE Engine Service Manual.

•	If resistance check is smooth and is close to the resistance values shown in the table below, fuel level senders are OK. Refer to procedures in the 2002-2003 VUE Powertrain Electrical Diagnostics Service Manual for additional diagnostics.

•	The following table can be used as a reference for fuel level sender readings.

Important: All readings are approximate.





Important: Due to the operation of the secondary venturi jet pump, it may be normal to have each sender read different resistance values. Only the resistance value of both senders should be compared to a known fuel level. The individual resistance values can be used when measuring a sender out of the tank.

Important: Code P0461, Fuel Level Sender Performance, is a Type D code, which means no warning lights are illuminated when this code sets. However, the ECM and BCM command the fuel gage to Empty position when this code is active. (The Low Fuel Light is NOT illuminated.)

The fuel gauge will not work properly unless one of the following occurs:

•	The code is cleared.

•	The test for P0461 passes.

4. Clear any DTCs in ECM history. The fuel gauge will not work until all fuel gauge codes have been cleared.
5. Verify fuel gauge is now operating correctly.

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 if another procedure is performed, refer to the appropriate Electronic Labor Time Guide for the correct Labor Operation Code and Time.