Fuel Pump Module: Removal

Release fuel system pressure. Refer to STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE PROCEDURE in this section.
Remove the battery cover and disconnect negative battery cable.
Remove the convertible top fasteners (15 nuts) (Fig 1 and Fig 2 ).

Fig 1: Removing Convertible Top Fasteners
Courtesy of DAIMLERCHRYSLER CORP.

Fig 2: Removing Convertible Top Fastener
Courtesy of DAIMLERCHRYSLER CORP.
Lift the top up and disconnect the heated back glass electrical connector (Fig 3 ) from both sides of the glass.

Fig 3: Disconnecting Back Glass Electrical Connector
Courtesy of DAIMLERCHRYSLER CORP.
Pull top forward and out of the way.
Roll deck lid carpet forward and out of the way.
NOTE: Be careful the sealer on the cover will make it difficult to remove the cover.
Remove the 4 rivets from the fuel pump module cover (Fig 4 ) and (Fig 5 ). You may have to knock out the center pin with a punch.

Fig 4: Locating Fuel Pump Module Cover
Courtesy of DAIMLERCHRYSLER CORP.

Fig 5: Removing Fuel Pump Module Cover And Rivets
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Using a scraper or long knife cut the sealer under the cover to remove it from the vehicle.
Remove the foam block from the top of the fuel pump module (Fig 6 and Fig 7 ).

Fig 6: Locating Fuel Pump Module Foam Block
Courtesy of DAIMLERCHRYSLER CORP.

Fig 7: Removing/Installing Foam Block
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Unlock and disconnect the electrical connector from the fuel pump module.
Clean the area round the fuel pump module.
Mark fuel pump module location on tank.
Disconnect the fuel line, wrap shop towels around ends of fuel supply line (Fig 8 ).

Fig 8: Disconnecting Fuel Pump Module Electrical & Fuel Connection
Courtesy of DAIMLERCHRYSLER CORP.
Use Special Tool #6856 to remove fuel pump module locknut (Fig 9 ).

Fig 9: Removing Fuel Pump Module Locknut Using Special Tool
Courtesy of DAIMLERCHRYSLER CORP.
Lift module up to remove being careful not to spill the residual fuel that is left in it. The float arm of the level sensor catches on the inside of the fuel tank while removing the module. Tilt the module assembly to one side while removing it. Discard old seal.