For 1990-2009 cars

### Removal Procedure

Notice: Do not attempt to disassemble the fuel sender assembly. Damage may occur to the sender assembly and the component parts. A re-assembled fuel sender assembly will not perform properly after installation to the vehicle.

1. Remove the fuel tank from the vehicle. Refer to Fuel Tank Replacement .
2. Disconnect the electrical connector (5) from the fuel sender assembly (4).
3. Remove the clamp and the fuel vapor hose (3) from the fuel vapor pipe on the fuel sender assembly (4).
4. Disconnect the quick-connect fuel return line (1) from the fuel sender assembly (4). Refer to Plastic Collar Quick Connect Fitting Service .
5. Disconnect the quick-connect fuel feed line (2) from the fuel sender assembly (4). Refer to Plastic Collar Quick Connect Fitting Service .
6. Remove the 6 screws that attach the fuel sender assembly to the fuel tank.
7. Remove the fuel sender assembly from the fuel tank.

### Installation Procedure

1. Install the fuel sender assembly to the fuel tank with a new gasket.

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.

2. Install the 6 bolts that secure the fuel sender assembly to the fuel tank.

Tighten
Tighten the bolts to 10 N·m (89 lb in).

3. Connect the fuel vapor hose (3) to the fuel vapor pipe on the fuel sender assembly (4), and secure the hose with the clamp.
4. Connect the quick-connect fuel return line (1) to the fuel return pipe on the fuel sender assembly (4). Refer to Plastic Collar Quick Connect Fitting Service .
5. Connect the quick-connect fuel feed line (2) to the fuel feed pipe on the fuel sender assembly (4). Refer to Plastic Collar Quick Connect Fitting Service .
6. Connect the electrical connector (5) to the fuel sender assembly (4).
7. Install the fuel tank to the vehicle. Refer to Fuel Tank Replacement .