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: Always replace the fuel sender O-rings when reinstalling the fuel sender assembly.

Tool Required

J 35731 Fuel Sender Spanner Wrench.

1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief W 3800, Fuel Pressure Relief W 3100, Fuel Pressure Relief W 3.4L.
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure W 3800, Fuel Tank Draining W 3100, Fuel Tank Draining Procedure W 3.4L.
3. Remove the fuel tank. Refer to Fuel Tank Replacement ,W 3800 Fuel Tank Replacement W 3100, Fuel Tank Replacement W 3.4L.
4. Clean all of the fuel pipe connections.
5. Clean all of the hose connections.
6. Remove the quick-connect fittings at the fuel sender assembly. Refer to Servicing Quick Connect Fittings W 3800, Servicing Quick Connect Fittings W 3100, Servicing Quick Connect Fittings W 3.4L.
7. Using the J 35731 Fuel Sender Spanner Wrench, remove the fuel sender assembly retaining cam, the fuel sender assembly and the O-ring from the fuel tank. Discard the fuel sender assembly O-ring.

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

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 W 3800, Servicing Quick Connect Fittings W 3100, Servicing Quick Connect Fittings W 3.4L.
5. Install the fuel tank. Refer to Fuel Tank Replacement ,W 3800 Fuel Tank Replacement W 3100, Fuel Tank Replacement W 3.4L.
6. Lower the vehicle.
7. Add fuel and install the fuel tank filler pipe cap.
8. Install the negative battery cable.
9. Inspect for leaks.

9.1.	Turn the ignition switch to the ON position for two seconds.

9.2.	Turn the ignition switch to the OFF for ten seconds.

9.3.	Turn the ignition switch to the ON position again.

9.4.	Check for fuel leaks.