For 1990-2009 cars

## Fuel Sender Assembly Replacement Replacement

### Removal Procedure

#### Tools Required

J 35731 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.

Notice: Replace the fuel sender O-rings when re-installing the fuel sender in order to avoid damage to the fuel sender assembly.

1. Relieve the fuel system fuel pressure. Refer to the Fuel Pressure Relief .
2. Drain the fuel tank. Refer to Fuel Tank Draining .
3. Clean all of the fuel pipe connections, all of the hose connections, and all of the areas surrounding the connections before disconnecting the connections in order to avoid possible contamination of the fuel system.
4. Remove the fuel tank. Refer to Fuel Tank Replacement

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5. Remove the quick-connect fittings at the fuel sender assembly (1). Refer to Servicing Quick Connect Fittings .

### Disassemble Procedure

1. Remove the fuel sender assembly retaining cam (1) , using the J 35731 Fuel Sender Spanner Wrench.
2. Remove the fuel sender assembly and the O-ring from the fuel tank.
3. Discard the fuel sender assembly O-ring.
4. Clean the fuel sender assembly O-ring sealing surfaces.
5. Inspect the fuel sender assembly O-ring sealing surfaces.

### Assemble 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.

1. Position the new fuel sender assembly O-ring on the fuel tank.
2. Assemble the fuel sender assembly and the fuel sender assembly retainer cam using the J 35731 Fuel Sender Spanner Wrench.

### Installation Procedure

1. Install the fuel tank. Refer to Fuel Tank Replacement .
2. Lower the vehicle.
3. Add fuel and install the fuel tank filler pipe cap.
4. Install the negative battery cable.
5. Inspect for leaks.

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

5.2. | Turn the ignition switch to the Off for ten seconds.

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

5.4. | Check for fuel leaks.