For 1990-2009 cars

#### Special Tools

• | J 39765 Fuel Sender Lock Nut Wrench

• | J 45722 Fuel Sender Lock Ring Wrench

### Removal Procedure

Caution: Refer to Gasoline/Gasoline Vapors Caution in the Preface section.

Caution: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.

1. Remove the fuel tank. Refer to Fuel Tank Replacement .
2. Disconnect the fuel tank harness electrical connector from the fuel pump module.
3. Remove the fuel tank harness from the retaining features on the fuel tank and remove the harness.
4. Remove the fuel feed and return lines from the retaining features (1) on the fuel tank.

Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring.

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.

Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.

5. Use the J 45722 (1) and a long breaker-bar in order to unlock the fuel sender lock ring. Turn the fuel sender lock ring in a counter-clockwise direction.

Important:

• | Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped.

• | Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring.

• | Check the lock ring for flatness.

6. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points.
7. If the warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
8. If the warpage is greater than 0.41 mm (0.016 in) the lock ring must be replaced.
9. Slowly lift the fuel pump module (2) up until the fuel level sensor float arm is just visible. Ensure that the fuel level sensor harness connector clears the tank opening.

Important: When removing the fuel pump module from the fuel tank, be aware that the pump module reservoir bowl is full of fuel. The reservoir must be tipped slightly during removal to avoid bending the fuel level sensor float arm.

10. Tilt the fuel pump module (2) toward the front of the fuel tank to enable the level sensor float arm to clear the tank opening. Remove the pump module (2) from the tank.
11. Remove the fuel pump module lock ring (1).
12. Discard the fuel in the pump module reservoir bowl into an approved fuel container.
13. If only replacing the module, remove the fuel level sensor. Refer to Fuel Level Sensor Replacement .

Important: Do NOT reuse the old fuel pump module-to-fuel tank seal.

14. Remove and discard the fuel pump module seal (3).

### Installation Procedure

1. Position a NEW fuel pump module seal (3) onto the fuel tank.
2. If installing only the module, install the fuel level sensor. Refer to Fuel Level Sensor Replacement .
3. Install the fuel pump module lock ring (1) over the module feed and return lines and into position on top of the module.

Important: The reservoir must be tipped slightly during installation to avoid bending the fuel level sensor float arm.

4. Tilt the fuel pump module (2) toward the front of the fuel tank to enable the level sensor float arm to clear the tank opening. Install the fuel pump module (2) to the fuel tank.
5. Slowly lower the fuel pump module (2) into the tank. Ensure that the fuel lines align with the cut outs in the tank.

Important:

• | Ensure that the fuel pump module lock ring is fully seated within the fuel tank retaining tab slots.

• | Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. Do not apply any type of lubrication in the seal groove. Ensure that the lock ring is installed with the correct side facing upward. A correctly installed lick ring will only turn in a clockwise direction.

6. Use the J 45722 (1) in order to install the fuel sender lock ring. Turn the fuel sender lock ring in a clockwise direction.
7. Secure the fuel feed and return lines to the retaining features (1) on the fuel tank.
8. Position the fuel tank harness and connect the fuel tank harness electrical connector to the fuel pump module.
9. Install the fuel tank harness to the retaining features on the fuel tank.
10. Install the fuel tank. Refer to Fuel Tank Replacement .