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Fuel Pump Module: Installation

  1. Wipe seal area of tank clean and place a new seal in position in the tank opening.
  2. Position fuel pump in the tank. Make sure the alignment tabs on the underside of the fuel pump module flange (Fig 1) sits in the notches on the fuel tank (Fig 2).
    Fig 1: Pump Module Notch
    G03498658Courtesy of DAIMLERCHRYSLER CORP.
    Fig 2: Fuel Tank Notch Locator
    G03498659Courtesy of DAIMLERCHRYSLER CORP.
  3. Position the locknut over the fuel pump module.
  4. Tighten the locknut using Special Tool #6856 to 55 N.m (40.5 ft. lbs.).
    CAUTION: Over tightening the pump lock ring may result in a leak.
  5. Raise the fuel tank on the transmission stand.
  6. Install fuel pump electrical connector into hole in the body.
  7. Connect the purge and vent lines.
  8. Raise tank into position and install tank straps.
  9. Install the fuel filler tube and tighten the clamp.
  10. Reposition the stabilizer bar and install bolts.
  11. Lower vehicle.
  12. Connect the fuel pump electrical connector that is in the rear seat.
  13. Install the rear seat.
  14. Connect the battery cable.
  15. Fill fuel tank. Use the DRB III® scan tool to pressurize the fuel system. Check for leaks.
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