Fuel Pump Module: Installation

WARNING: This page is about a different car, the 2008 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 lock nut (lock ring) and lock nut 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).

Fig 1: Removing/Installing Float Rod Clip

Courtesy of CHRYSLER LLC

1 - FUEL LEVEL SENSOR

2 - CLIP

3 - FLOAT ROD

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

Fig 2: Removing/Installing Float Rod Clip

Courtesy of CHRYSLER LLC

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 lock nut over top of fuel pump module. Install lock nut 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 lock nut. This step must be performed to prevent the module's float from contacting the side of fuel tank.
Tighten lock nut using Special Tool #6856. Refer to SPECIFICATIONS .
Install fuel tank.

Fig 3: Align Pump Module

Courtesy of CHRYSLER LLC

1 - LOCK NUT

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