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Module-Fuel Pump: Removal

  1. Release the fuel pressure, refer to the Fuel Pressure Release Procedure .
  2. Disconnect negative battery cable.
    NOTE: The fuel level of the vehicle must be below 5/8 of a tank before you remove the module lock-rings. If it is above that you can spill fuel in the vehicle.
    Fig 1: DRAINING FUEL
    GC0013027Courtesy of DAIMLERCHRYSLER CORP.
  3. Drain partial fuel from fuel tank through the filler tube. Use a hard nylon tube, with a 30° cut on the end, to push the check valve open to drain fuel from tank.
    Fig 2: REAR SEAT
    GC0013028Courtesy of DAIMLERCHRYSLER CORP.
  4. Remove the rear lower seat cushion.
    Fig 3: REAR SEAT UP
    GC0013029Courtesy of DAIMLERCHRYSLER CORP.
  5. Push seat back and up to remove seat cushion.
    Fig 4: FOAM PAD UNDER SEAT
    GC0013033Courtesy of DAIMLERCHRYSLER CORP.
  6. Fold back the foam pad covering access cover for modules.
    Fig 5: LEFT SIDE MODULE ORIENTATION
    GC0013034Courtesy of DAIMLERCHRYSLER CORP.
  7. Disconnect the electrical connector from left side module.
  8. Mark the module orientation.
    Fig 6: TOOL 9430 LEFT SIDE MODULE
    GC0013036Courtesy of DAIMLERCHRYSLER CORP.
  9. Use special tool #9340 to remove left side module lock ring.
    Fig 7: DRAINING LEFT SIDE
    GC0013035Courtesy of DAIMLERCHRYSLER CORP.
  10. Drain fuel from left side of fuel tank. Lift module up enough to push hose into tank and drain. Do not spill fuel in interior of vehicle.
    Fig 8: MODULE ELECTRICAL CONNECTORS
    GC0013053Courtesy of DAIMLERCHRYSLER CORP.
  11. Disconnect the electrical connectors from the module top.
  12. Remove the module top half.
    Fig 9: PUMP MODULE DR SIDE
    GC0013054Courtesy of DAIMLERCHRYSLER CORP.
  13. The module fuel level sending card (1). The fuel return lines (2). The fuel supply line (3).
    Fig 10: RELEASE TAB
    GC0013049Courtesy of DAIMLERCHRYSLER CORP.
  14. Fuel line release tab, press in the tab and pull up on fuel line.
    Fig 11: LINE RELEASE
    GC0013048Courtesy of DAIMLERCHRYSLER CORP.
  15. Remove fuel line.
    Fig 12: HOSE CONNECTIONS DR SIDE
    GC0013056Courtesy of DAIMLERCHRYSLER CORP.
  16. Remove fuel return line from lower module. Line unsnap from module.
    Fig 13: HOSE CONNECTIONS
    GC0013051Courtesy of DAIMLERCHRYSLER CORP.
  17. Return line removed.
    Fig 14: HOSE CONNECTIONS AT PUMP
    GC0013052Courtesy of DAIMLERCHRYSLER CORP.
  18. Tip module on its side to drain remaining fuel from reservoir and remove module from vehicle.
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