For 1990-2009 cars

### Removal Procedure

### Tools Required

• | J 34730 Fuel Pressure Gauge

• | J 35731 Fuel Sender Spanner Wrench

1. Relieve the fuel system fuel pressure. Refer to the Fuel Pressure Relief .
2. Drain the fuel tank (1). Refer to Fuel Tank Draining .
3. Remove the fuel tank. Refer to Fuel Tank Replacement .
4. Remove the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .

### Disassemble Procedure

1. Inspect the position of the fuel pump fuel strainer (3) for installation.
2. Support the fuel pump (4) with one hand and grasp the fuel pump fuel strainer with the other hand
3. Pull the fuel pump fuel strainer off of the fuel pump.
4. Inspect the fuel pump fuel strainer. If the fuel pump fuel strainer is contaminated, the fuel tank should be cleaned.
5. Discard the fuel pump fuel strainer after inspection.
6. Inspect the fuel pump inlet for dirt and debris. If dirt and debris are found, the fuel pump should be replaced.
7. Remove the fuel pump electrical connector, if fuel pump is being replaced.
8. Place the fuel sender assembly upside down on a bench.

Notice: In order to prevent damage to the fuel pump, Do Not run the fuel pump unless the fuel pump is submerged in fuel.

9. Pull the fuel pump downward in order to remove the fuel pump from the fuel pump mounting bracket, then tilt the fuel pump outward and remove the fuel pump from the fuel feed pipe.
10. Transfer the fuel pump to the new fuel sender, if fuel sender is being replaced,

### Assemble Procedure

1. Install the rubber insulator on the fuel pump.
2. Position the fuel sender assembly (1) upside down.

Important: Always install a new fuel pump fuel strainer when installing a fuel pump.

3. Install the fuel pump between the fuel feed pipe and the fuel pump mounting bracket.
4. Install the fuel pump electrical connector.
5. Position the new fuel pump fuel strainer (3) on the fuel pump and push on the outer edge of the fuel pump fuel strainer until the fuel pump fuel strainer is fully seated.

### Installation Procedure

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.

1. Install the fuel sender assembly (1). Refer to Fuel Sender Assembly Replacement .
2. Install the fuel tank. Refer to Fuel Tank Replacement .
3. Lower the vehicle.
4. Add fuel and install the fuel tank filler pipe cap.
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. | Check for fuel leaks.