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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. Install gasket on fuel tank.
  3. Position the locknut over the fuel pump module.
  4. Seat Fuel Pump Module in tank by pushing down on it, align the fuel pump module with mark on tank. Make sure that the level sensor float arm is forward in the tank.
  5. Hand tighten the lock nut, then torque to 55 N.m (40 ft. lbs.) using Special tool #6856.
    CAUTION: Over tightening the pump lock ring may result in a leak.
  6. Connect and lock the electrical connector to the fuel pump module.
  7. Connect fuel line to the fuel pump module. Refer to QUICK-CONNECT FITTINGS  in the Fuel Delivery Section of this group.
  8. Fill fuel tank.
  9. Connect negative battery cable.
  10. Use the DRBIII(R) Scan Tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.
  11. Disconnect negative battery cable.
  12. Install the foam block to the top of the fuel pump module (Figure and Figure ).
  13. Install the fuel pump module cover using sealer and rivets.
  14. Roll deck lid carpet back in place.
  15. Pull top back and install the heated back glass electrical connector (Figure )
  16. Install the convertible top fasteners (15 nuts) (Figure and Figure ).
  17. Connect negative battery cable. Install the battery cover.
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