For 1990-2009 cars

### Removal Procedure

Caution: Provide additional support when a vehicle is on a hoist:

• | Before removing parts, support the opposite end. This helps prevent the vehicle from slipping off.

• | Before removing major components, chain the vehicle frame to the hoist pads at the same end as the removal. This helps avoid a tip-off.

Failure to follow these precautions could cause vehicle damage, serious personal injury, or death.

Notice: Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle.

Important: Important do not attempt to repair sections of nylon fuel pipes. If the nylon fuel pipes are damaged, replace them.

1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief
2. Drain the fuel tank. Refer to Fuel Tank Draining
3. Raise the vehicle.
4. Remove the fuel tank filler hose from the fuel tank.
5. Remove the fuel tank filler vent hose from the fuel tank.
6. Remove the fuel sender assembly electrical connector.
7. Remove the EVAP connecting hose at the fuel sender pipe.
8. Remove the quick-connect fittings at the fuel tank. Refer to Servicing Quick Connect Fittings
9. Remove the exhaust pipe heat shield screws
10. With the aid of an assistant, support the fuel tank, and remove the fuel tank strap attaching bolts which retain the fuel tank straps.
11. Remove the fuel tank from the vehicle and place the fuel tank in a suitable work area.
12. Remove the fuel sender assembly. Refer to Fuel Sender Assembly Replacement
13. Remove the fuel feed and fuel return pipe assemblies and the insulator clips from the fuel tank.
14. Remove the insulator pads from the fuel tank. Note the location of the insulator pads for installation.

### Installation Procedure

1. Clean the fuel sender assembly O-ring sealing surfaces.
2. Position the new fuel sender assembly O-ring on the fuel tank.

Important: 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.

3. Install the fuel sender assembly and the fuel sender assembly retainer cam using the J 35731 Fuel Sender Spanner Wrench
4. Install the quick-connect fittings at the fuel sender assembly. Refer to Servicing Quick Connect Fittings .
5. Install the fuel tank. Refer to Fuel Tank Replacement .
6. Lower the vehicle.
7. Add fuel and install the fuel tank filler pipe cap.
8. Install the negative battery cable.
9. Inspect for fuel leaks.

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

9.2. | Turn the ignition switch to the OFF for 10 seconds.

9.3. | Again turn the ignition switch to the ON position.

9.4. | Check for fuel leaks.