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thank you for the excellent description. I was able to follow it easily and get to the sensor. Unfortunalty, all the wires were in good shape and I did not see any problem with the connection. Time for a new sensor?
Interesting that the car stalled when I pulled the sensor while running?
thanks
Nathan
Glad it helped. Another question for you - did you actually see a wire that was run beneath the float arm on the body of the sender? If not, it may have broken off completely. Here's a picture of where the wire is:
Also, on the backside there is a small circuit board (which you can see in the picture as well) that is contacted by a wiper point - as you swing the float arm through its range of motion, yo'ull see it contact a number of solder points. Try cleaning those. Finally, did you check the electrical contacts on the pump unit itself, where the harness for the sender plugs in? Even if the contact points on the sender harness are clean, the socket they plug into could be dirty.
If none of that fixes it, I'd say you're in for a new sender. Let me know what happens OK?
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Replace the instrument cluster . GM had stepper motor issues 2003 to 2006 . Pin out won't help you , The info for the instrument cluster gauges come's over class 2 serial data buss (network) from the PCM - engine computer . Do you know what GM class 2 data network is ? All gauge info comes over one wire from the PCM . How to repair GM Instrument Cluster Speedometer Gauge Stepper Buick Class 2 Operation Diagnosis 1998
Hooking up a Tech 2 scan tool an checking for code's an data to the instrument cluster would be the correct diagnostic procedure . But you wouldn't know that , not being a Chevy technician . Not having factory service repair info. manual .
Speedometer
The IPC displays the vehicle speed based on the information from the PCM. The PCM calculates the vehicle speed from the vehicle speed sensor (VSS) circuit. The IPC receives a class 2 message from the PCM indicating the vehicle speed. The PCM also calculates the vehicle speed based on the wheel reference vehicle speed class 2 message from the EBCM. The PCM uses the vehicle speed information from the EBCM as a backup. The IPC displays the vehicle speed information from the EBCM when the PCM detects a malfunction in the vehicle speed sensor circuit.
The speedometer defaults to 0 km/h (0 mph) if the IPC detects a loss of class 2 communications with both the PCM and the EBCM.
Engine Coolant Temperature (ECT) Gage
The IPC displays the engine coolant temperature on the analog ECT gage as determined by the PCM. The PCM monitors the signal circuit of the engine coolant temperature sensor. The IPC receives a class 2 message from the PCM indicating the engine coolant temperature. The IPC illuminates the check gages indicator when a high engine coolant temperature condition exists. The engine coolant temperature gage defaults to 75°C (160°F) or below when one of the following conditions occur:
• The PCM detects a malfunction in the engine coolant temperature sensor signal circuit.
• The IPC detects a loss of class 2 communication with the PCM.
For additional informatin on the engine cooling system, refer to Cooling System Description and Operation in Engine Cooling.
Engine Oil Pressure (EOP) Gage
The IPC displays the engine oil pressure on the analog EOP gage as determined by the PCM. The PCM monitors the signal circuit of the engine oil pressure sensor. When the engine oil pressure sensor resistance is high, the engine oil pressure is high. When the engine oil pressure sensor resistance is low, the engine oil pressure is low. The IPC receives a class 2 message from the PCM indicating the engine oil pressure. The IPC illuminates the check gages indicator when a low oil pressure condition exists. The engine oil pressure gage defaults to 0 kPa (0 psi) when the following condition occurs:
• The PCM detects a malfunction in the engine oil pressure sensor signal circuit.
• The IPC detects a loss of class 2 communication with the PCM.
Fuel Gage
The IPC displays the fuel level on the analog fuel gage as determined by the PCM. The PCM monitors the signal circuit of the fuel level sensor. When the fuel level sensor resistance is high, the fuel gage indicates full. When the fuel level sensor resistance is low, the fuel gage indicates empty. The IPC receives a class 2 message from the PCM indicating the filtered fuel level percent. The PCM uses 2 filters for the fuel level percent. The slow filter is used during normal operation. The fast filter is used when the engine is just started or when the vehicle is in Park or Neutral. The fast filter allows the fuel gage to reach the current fuel level quickly. The fuel gage defaults to empty when the following conditions occur:
• The PCM detects a malfunction in the fuel level sensor circuit. Refer to Diagnostic System Check - Instrument Cluster .
• The IPC detects a loss of class 2 communications with the PCM.
Reviewing the fuel system description will further explain how the system functions. Refer to:
• Fuel System Description in Engine Controls - 4.3L
• Fuel System Description in Engine Controls - 4.8L, 5.3L, and 6.0L.
O2 sensor needs to be replaced when you get low gas mileage in car. The procedure to replace is as follows: ---- 1) The oxygen sensor is located under the car. 2) Put the car on jack stands on the rack, this will give you proper sensor location in the car. 3) The sensor has to be turned a bit then it can be easily removed. 4) Most of the times the O2 sensor comes out very easily but if its bit hard to remove it then you can use "FREEZE spray" to make it gets loose. 5) The spray will make it come out easily. 6) When the O2 sensor is getting removed, some of thewiring'swill also come out. 7) Before removing the O2 sensor, take the note of thewiring'sand the position of wiring so while inserting new O2 sensor youdon'tget confused. 8) Now after you remove the old faulty O2 sensor out. Carefully insert new O2 sensor in same position. 9) And reverse/refit all the wires / parts which you removed while replacing the old O2 sensor. This will help. Thanks.
You have either bad fuel gauge or fuel level sensor.
I had replaced few level sensors on AUDIs , and never the gauge , but who knows.
The test with diagnostic scaner needs to be performed for instrument cluster and after that it may verify one out of two - gauge or sensor.
Have the speed sensor checked, that's mounted on the side of the tranny, that operates the speedometer. As far as the fuel gauge, probably the fuel sending unit is shot which is in the gas tank.
changing the engine sensor is easy when engine is cold and make sure you refill with antifreeze ,Buy sensor first so you know what to look for its not expensive from a motor factor .i honestly cant remember ever changing one on this model but it must be around the head area somewhere
cooling fan has a relay. check it first. Then check the ECT, Engine Coolant Temperature Sensor. It is on the engine and sends a signal to the PCM, Engine Computer.
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Section 03-03: Engine Cooling
1996 Aspire Workshop Manual
DESCRIPTION AND OPERATION
Cooling Fan, Electric
WARNING: WHEN WORKING IN THE ENGINE COMPARTMENT, STAY CLEAR OF THE FAN BLADE. BECAUSE IT IS ELECTRIC AND TEMPERATURE SENSITIVE, IT CAN START AT ANY TIME IF THE IGNITION IS ON.
The electric cooling fan is an electro-drive type. Its operation depends upon engine temperature and ignition switch (11572) position. If engine coolant temperature reaches 97°C (207° F) and the ignition switch is in the ON position, the engine coolant temperature sensor (ECT sensor) (12A648) sends a signal to the powertrain control module (PCM) (12A650) which turns the engine cooling fan motor (8K621) and fan blade assembly on. Because it cannot operate unless the ignition switch is ON, the engine cooling fan motor and fan blade assembly does not operate after engine shutdown.
The fan control relay (FC relay) is located in the LH front corner of the engine compartment, between the battery (10655) and the headlamp assembly. Circuit protection is provided by a 30A fuse labeled COOLING FAN in the main fuse junction panel to the left of the battery.
If the vehicle is equipped with air conditioning, an additional relay is installed in the circuit. The A/C clutch control relay (19D572) bypasses the engine temperature portion of the circuit. The bypass circuit allows the engine cooling fan motor to operate whenever the A/C switch is engaged.
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------------------------------------------------------------------------------------------ Fuel pump/sender access is through cover under rear seat.
Fuel Gauge
Remove the instrument cluster. Refer to the procedure in this section.
Using a jumper, connect the battery positive terminal to the fuel gauge "+" terminal and the battery negative terminal to the fuel gauge "-" terminal.
Connect one lead of a Rotunda Instrument Gauge System Tester 014-R1063 or equivalent to the "F-U" terminal of the fuel gauge (9280), and connect the other lead to the "-" terminal of the fuel gauge.
Adjust the instrument gauge system tester to the resistances shown in the illustration.
If the fuel gauge does not operate as specified, replace the fuel gauge. If the fuel gauge is OK, return to the Pinpoint Test.
Fuel Level Sensor
Remove the fuel level sensor (9275). Refer to Section 10-01 for the removal procedure.
Measure the resistance between terminal A and terminal B of the fuel level sensor.
Connector Shown From Component Side
Adjust the fuel tank float to the following positions:
If the resistances are not as specified, replace the fuel level sensor. If the fuel level sensor is OK, return to the Pinpoint Test.
How do I locate the sensor on a 2003 A4 1.8L? I see a blue sensor on the right by the firewall, and a green sensor on the left nearer to the battery on the left. Is it possible that I already have a green sensor in my car?
WARNING: WHEN WORKING IN THE ENGINE COMPARTMENT, STAY CLEAR OF THE FAN BLADE. BECAUSE IT IS ELECTRIC AND TEMPERATURE SENSITIVE, IT CAN START AT ANY TIME IF THE IGNITION IS ON. 
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J_del,
thanks, that worked out great. Once I got down into the tank and figured out how to pull the float, I managed to replace it without blowing myself up.
the wire was so shot I went for the new unit vs messing around creating a new wire.
thanks again for the solution,
nathan
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