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Fuel Sending Unit - Repair 1 Saabers Like This Post!
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Posted by Matt Grimes [Email] (#2198) [Profile/Gallery] (more from Matt Grimes) on Wed, 26 Jul 2017 19:57:47 Share Post by Email
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The fuel gauge was not working when I bought the car. I assumed the sending unit was likely bad, possibly a sunk float. After removing the floor in the boot I found the access hole to the sending unit (on the passenger side). I unplugged the connector and after consulting the wiring diagram, used a jumper wire between the black wire (Gnd) and the brown wire going to the Low Fuel lamp on the dash. This caused the Low Fuel lamp to light up. Then I moved the jumper wire over to the gray wire and sure enough, the fuel gauge rose to Full. So, the power source, gauge, and wiring are all good.

The sending unit itself had a ribbed black plastic ring that needs to be unscrewed. What worked for me was using an oil filter wrench, the kind that look like a large funky pair of pliers. There was enough room to get the ends down around the ring (from the top) and twist it loose.

In theory you should be able to separate the plastic ring from the sending unit and lift out the sending unit. In this case the top of the sending unit had come disconnected from the bottom part which was laying in the bottom of the tank with a thin wire connecting them together. I was able to use the wire to carefully lift the unit out of the tank. It's hard to believe that it could come apart in this manner but it sure did.

Now I need to figure out how to re-solder the wires and reassemble it. I labeled the photograph...
D & E are still soldered to the thin wire and the other end of the thin wire is soldered at C
It looks like the two wires from the long tube, G & H, are supposed to be soldered to B & C.
I'm guessing that A & F used to be one piece and that it simply broke in two.

Can anyone confirm this?



->Posting last edited on Wed, 26 Jul 2017 20:00:26.
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900 Turbo Convertible - 1991, Automatic
Enhancements: Swedish Dynamics Stage 4 Red Series APC, Fuel injector set, and EPROM(Fuel "Chip") for the BOSCH 2.4 LH fuel management system!
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Colorado Springs, CO
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