For 1990-2009 cars

### Removal Procedure

### Tools Required

• | J 34730-1A Fuel Pressure Gauge

• | J 39765 Fuel Sender Lock Nut Wrench

Caution: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

Caution: Provide proper ventilation when working with fuel in enclosed areas where fuel vapors can collect. The lack of adequate ventilation may result in personal injury.

Caution: Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash.

Notice: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system:

• | The fuel pipe connections

• | The hose connections

• | The areas surrounding the connections

Important: When removing the modular fuel sender assembly from the fuel tank, the reservoir bucket on the fuel sender assembly is full of fuel. The modular fuel sender assembly must be tipped slightly during removal in order to avoid damage to the float. Place any remaining fuel into an approved container once the modular fuel sender assembly is removed from the fuel tank.

1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief .
2. Drain the fuel tank to at least 3/4 of a tank full. Refer to Fuel Tank Draining .
3. Remove the spare tire cover, the jack, and the spare tire.

Caution: Remove the rear compartment floor trim to provide technician contact with the vehicle's metal surfaces. Failure to remove the rear compartment floor trim may cause a static electricity discharge to ignite any fuel vapor resulting in personal injury and vehicle damage.

Notice: Remove the rear compartment floor trim to avoid damage from fuel spillage.

4. Remove the rear compartment floor trim. Refer to Rear Compartment Trim Panel Replacement in Body and Accessories.
5. Remove the bolts from the fuel sender access panel.

Notice: In order to prevent damage, cover the fuel pipe fittings with a shop towel before disconnecting the fuel pipes or removal of the fuel sender retaining ring, in order to catch any fuel that may leak out. Place the towel in an approved container when procedure is completed.

6. Remove the quick-connect fittings at the fuel sender assembly. Refer to Metal Collar Quick Connect Fitting Service .
7. Remove the electrical connectors at the fuel sender.

Important: The modular fuel sender assembly will spring-up when the locking ring is removed.

8. Remove the fuel sender retaining ring using the J 39765 Fuel Sender Spanner Wrench.

Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints.

9. Pull the modular fuel sender straight up while allowing fuel to drain from the reservoir.
10. Remove the fuel sender from the trunk.
11. Place the fuel sender in an approved container.
12. Clean the fuel sender assembly O-ring sealing surfaces.
13. Inspect the fuel sender assembly O-ring sealing surfaces.

### Installation Procedure

Important: Care should be taken not to fold over or twist the fuel pump strainer when installing the fuel sender assembly, as this will restrict fuel flow. Also, assure that the fuel pump strainer does not block full travel of float arm.

Important: Always replace the fuel sender O-rings when reinstalling the fuel sender assembly.

1. Position the new fuel sender assembly and O-ring on the fuel tank.
2. Install the fuel sender assembly and the fuel sender assembly retainer cam using the J 39765 Fuel Sender Spanner Wrench.
3. Install the quick-connect fittings at the fuel sender assembly. Refer to Metal Collar Quick Connect Fitting Service .
4. Install the electrical connector at the fuel sender.
5. Install the negative battery cable. Refer to Battery Cable in Engine Electrical.
6. Inspect for leaks.

6.1. | Turn the ignition switch to the On position for 2 seconds.

6.2. | Turn the ignition switch to the Off for 10 seconds.

6.3. | Turn the ignition switch to the On position.

6.4. | Visually inspect the fuel system for fuel leaks.

7. Install the fuel sender access panel.

Tighten
Tighten the bolts to 2 N·m (18 lb in).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

8. Install the rear compartment floor trim. Refer to Rear Seat Cushion Replacement in Body and Accessories.
9. Install the spare tire, the jack, and the spare tire cover.
10. Add fuel and install the fuel tank filler pipe cap.
11. Add fuel and install the fuel tank filler pipe cap.

11.1. | Turn the ignition switch to the ON position for 2 seconds.

11.2. | Turn the ignition switch to the OFF position for 10 seconds.

11.3. | Turn the ignition switch to the ON position.

11.4. | Visually inspect the fuel system for fuel leaks.

12. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement in Body and Accessories.