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Home >> Saturn >> 2000 >> SW2 Automatic >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System - Testing & Engine Component Testing >> Engine Sensors & Switches >> Fuel Level Sensor >> 1.9L, 2.2L 3.0L, 3.4L & 3.8L
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1.9L, 2.2L 3.0L, 3.4L & 3.8L

  1. Check instrument cluster operation. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. Repair as necessary. If instrument cluster and circuits are okay, go to next step.
  2. Install scan tool. Turn ignition on. Using scan tool output control function, perform FUEL GAUGE SWEEP TEST. If fuel gauge sweeps through full range, go to next step. If fuel gauge does not sweep through full range, repair fuel gauge. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT.
  3. Turn ignition off. Raise and support vehicle. Disconnect fuel tank pigtail harness from body connector. Connect DVOM between fuel level sensor input circuit (Purple wire) and fuel level sensor ground circuit (Black wire on 2.2L and 3.0L; Black/White wire on all others) at body connector. Lower vehicle. Turn ignition on. If voltage is about 5 volts, go to next step. If voltage is not about 5 volts, go to step  5.
  4. Check for open in fuel level sensor input circuit (Purple wire) or fuel level sensor ground circuit (Black wire on 2.2L and 3.0L; Black/White wire on all others). Also, check for poor terminal connections at fuel level sensor pigtail harness. If problem does not exist, go to step  9. If problem exists, repair as necessary and go to step  12.
  5. If voltage is greater than 5 volts in step  3, go to step  10. If voltage is less than 5 volts in step  3, go to next step.
  6. Connect DVOM between fuel level sensor input circuit (Purple wire) at body connector and chassis ground. If voltage is about 5 volts, go to next step. If voltage is not about 5 volts, go to step  8.
  7. Locate and repair open in fuel level sensor ground circuit (Black wire on 2.2L and 3.0L; Black/White wire on all others). Also, check for poor terminal connections at fuel level sensor pigtail harness. After repairs, go to step  12.
  8. Check for open or short to ground in fuel level sensor input circuit (Purple wire). If problem does not exist, go to step  10. If problem exists, repair as necessary and go to step  12.
  9. Replace fuel level sensor. After repairs, go to step  12.
  10. Locate and repair short to voltage in fuel level sensor input circuit (Purple wire). After repairs, go to step  12.
  11. Replace PCM. After repairs, go to next step.
  12. Recheck system for proper operation. If system is not operating properly, repeat step  1.
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