Appreciated sir

Update: replaced fuel pump & sender assembly
 

Update: replaced fuel pump & sender assembly with the A-Premium from Amazon.

I don’t know what went wrong with my attempt at testing the gauge which seemed to indicate the gauge/PCM was the problem.
Because in the end, it seems the gas tank sending unit was the problem.

Sense a new unit is so affordable I decided to purchase the a premium unit on Amazon and install. So far the problem is completely resolved. Although I know after install, I had exactly 6 gallons of gas in the tank. The gauge showed about 7 gallons. Which is probably as accurate as when the car was new. When I installed the pump, I followed the service manual and found that a 5/32 drillbit did in fact just fit between the filter and sock and the float without any adjusting-bending the arms elbow.
I estimated that if I had used a 9/16” little bit in the gauge would’ve shown 6 gallons instead of seven but would then show empty a little sooner.

I did have to free rent a fuel pump tool kit from AutoZone because I could not reinstall the tank retaining ring without the twist socket wrench tool.
I’ve added some pictures below.

I left the following review on Amazon, which included brief instructions on replacing the tank pump:
The product pic is of the oem original pump. This one is a redesign so its top & bottom are the nylon plastic, not a metal bottom section. Which seems to work just fine. Comes with tank ring o ring, and 3 new fuel lines & clips. Before install place pump on ground, flatten sock & Check gap between float bottom and filter sock top. Adjust bend 90° angle of float arm so that a 9/16” (manual says 5/32 but I found gave a 1 gal. High reading at half tank) drill bit Just passes through this gap. To remove Gas Tank, drive Saturn until tank is Almost empty(Carry a spare gas can in case you run out, try not to). Block front tire with Two large rocks. Release fuel line pressure at Schrader test valve by brake master cylinder. Place Bottle Jack under center of Rear axle and raise. Place a Jack Stand In front of each rear tire under frame. Lower onto stands. Add wood under jack so you can raise even higher until it is high enough for the gas tank cage to Fully drop down(measure “ needed), Opened above ground. Drop on jackstands. Disconnect fuel lines at filter by squeezing clips. 10 mm socket remove Filler neck midsection bolt , Screwdriver to remove rubber filler tank clamp. 18 mm socket for the Two cage Bolts. Filler hose end has an internal 2” anti siphon part that must clear the tank mouth to drop. May need to use a short pry pole to aid needed separation clearance.
Pliers to remove small hose clamp & patiently wiggle hose off small plastic pipe. Unplug with your hand the two harnesses at top of gas tank As soon as reachable.
Reinstall: rent lock ring tool from auto store if needed, fill pump housing with some gas when placed in tank for much easier engine start, If driver side cage hinge pin is not seated properly, Cage will close short-bolt won’t fit.


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Thanks for stopping back.

Glad you got it figured out.

Now come to my house and redo mine.

Please.

Tempting. I like meeting and maybe sticking my hand down another guy’s tool box and seeing what’s inside.

Glad for the support of this great site and that I can share my mistakes and successes for anyone dealing with the same problem.

That is one of the creepiest comments anyone has ever posted on this forum.

:eek: