Fuel Sender Assembly Replacement. Geo Prizm 1997

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 maintain cleanliness when servicing fuel system components.

1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief.
2. Remove the rear seat bottom cushion. Refer to 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.
7. Disconnect the fuel feed line (3) from the fuel sender assembly.
8. Disconnect the fuel return line (4) from the fuel sender assembly.
9. Remove the eight fuel sender assembly hold down bolts (2).
10. Remove the fuel sender (1) from the fuel tank.

### 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. Install the fuel sender (1) to the fuel tank.
2. Secure the fuel sender to the fuel tank with the eight bolts (2).

Tighten
Tighten the bolts to 4 N·m (35 lb in).

3. Connect the fuel return line (4) to the fuel sender assembly.
4. Connect the fuel feed line (3) to the fuel sender assembly.
5. Connect the fuel sender assembly electrical connector.
6. Connect the negative battery cable.

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

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