For 1990-2009 cars

### Removal Procedure

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.

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.

Caution: Fuel Vapors can collect while servicing fuel system parts in enclosed areas such as a trunk. To reduce the risk of fire and increased exposure to vapors:

• | Use forced air ventilation such as a fan set outside of the trunk.

• | Plug or cap any fuel system openings in order to reduce fuel vapor formation.

• | Clean up any spilled fuel immediately.

• | Avoid sparks and any source of ignition.

• | Use signs to alert others in the work area that fuel system work is in process.

Notice: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.

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

Important: Always maintain cleanliness when servicing fuel system components.

Important: Do not bend the arm of the fuel gauge float while removing the fuel sender assembly.

1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief .
2. Remove the rear seat bottom cushion. Refer to Rear Seat Cushion Replacement in Body and Accessories.
3. Remove the left side door opening sill plate.
4. Fold back the carpet in order to maintain metal-to-metal contact while servicing the fuel sender assembly.
5. Remove the fuel sender assembly access panel (1) from the rear seat floor (the panel is held in place by a butyl caulk seal).
6. Disconnect the fuel sender assembly electrical connector (1).
7. Remove the fuel line fitting retaining clip (1).
8. Remove the fuel line (2) from the fuel sender assembly.
9. Remove the eight fuel sender assembly hold down bolts (2).
10. Remove the fuel sender assembly hold down plate (1).
11. Clean the fuel pipe and fuel sender assembly to prevent possible fuel contamination during removal.
12. Remove the fuel sender assembly (1) from the fuel tank (3).
13. Clean the fuel sender assembly O-ring sealing surfaces.
14. Inspect the fuel sender assembly O-ring sealing surfaces.

### Installation Procedure

Notice: Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware.

Do not repair sections of fuel pipes.

1. Position the new fuel sender assembly O-ring (2) on the fuel sender assembly (1).
2. Install the fuel sender assembly (1) into the fuel tank (3).
3. Install the fuel sender assembly hold down plate (1).

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.

4. Secure the fuel sender assembly hold down plate with eight bolts (2).

Tighten
Tighten the fuel sender assembly hold down plate bolts to 4 N·m (53 lb in).

5. Install the fuel pipe (2) to the fuel sender fitting.
6. Secure the fuel pipe (2) with the retaining clip (1).
7. Connect the fuel sender assembly electrical connector (1).
8. Connect the negative battery cable.

Tighten
Tighten the negative battery cable terminal retainers to 15 N·m (11 lb ft).

9. Pressurize the fuel system and check for leaks.
10. Inspect the fuel sender access panel (1) butyl caulk seal.
11. Replace any missing butyl caulk as necessary.
12. Install the fuel sender assembly access panel (1) to the rear seat floor.
13. Relocate the carpet under the seat and left sill plate area.
14. Install the left side door opening sill plate.
15. Install the rear seat bottom cushion. Refer to Rear Seat Cushion Replacement in Body and Accessories.