Fuel Pump Module: Installation

WARNING: This page is about a different car, the 2006 Dodge Sprinter. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: Whenever the fuel pump module is serviced, the rubber gasket must be replaced.

Thoroughly clean locknut (lockring) and locknut threads at top of tank.
Position new gasket (seal) to fuel tank opening.
Position float rod assembly partially into fuel tank.
Position fuel pump module partially into fuel tank.

Twist rod (3) into clip (2) on fuel level sensor (1). See Fig 1.

Fig 1: FLOAT ROD CLIP REMOVAL/INSTALLATION

Courtesy of DAIMLERCHRYSLER CORP.

1 - FUEL LEVEL SENSOR

2 - CLIP

3 - FLOAT ROD

Rotate clip (2) to attach rod (3) to clip. See Fig 2.

Fig 2: FLOAT ROD CLIP REMOVAL/INSTALLATION

Courtesy of DAIMLERCHRYSLER CORP.

1 - FUEL LEVEL SENSOR

2 - CLIP

3 - FLOAT ROD

After attaching float assembly to fuel level sensor, carefully position fuel pump module into opening in fuel tank.
Position locknut over top of fuel pump module. Install locknut finger tight.
The fuel line fittings should be pointed to the right side of the vehicle. Rotate and position alignment arrow towards right side of vehicle (if necessary) before tightening locknut. See Fig 3. This step must be performed to prevent the module's float from contacting the side of fuel tank.
Tighten locknut using Special Tool #6856. Refer to TORQUE SPECIFICATIONS.
Install fuel tank. Refer to FUEL TANK Removal/Installation.

Fig 3: ALIGN PUMP MODULE

Courtesy of DAIMLERCHRYSLER CORP.

1 - LOCKNUT

2 - ALIGNMENT ARROW (POSITION TOWARDS RIGHT SIDE OF VEHICLE)