Module, Fuel Pump: Installation: Installation

Fig 1: Fuel Pump Module Seal

Courtesy of CHRYSLER GROUP, LLC

WARNING:

Risk of injury to eyes and skin from contact with fuel. Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked and approved containers. Failure to follow these instructions may result in possible serious or fatal injury.

CAUTION:

Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced.

Clean the rubber O-ring seal area of the fuel tank and install a new rubber O-ring seal.
Lower the fuel pump module into the fuel tank using caution not to bend the float arm.
NOTE:
The fuel pump module must be properly located in the fuel tank for the fuel level gauge to work properly.
Align the rubber O-ring seal and rotate the fuel pump module to the orientation marks noted during removal. This step must be performed for the fuel level gauge to work properly.

Fig 2: Fuel Pump Module, Locking Ring & Lock Ring Wrench
Courtesy of CHRYSLER GROUP, LLC
Position the lock-ring (3) over top of the fuel pump module (4).
Position the lock-ring remover/installer (2) (special tool #9340, SAE Fuel Pump Lock Ring Wrench) into the notches on the outside edge of the lock-ring (3).
Install a 1/2 inch drive breaker bar (1) into the lock-ring remover/installer (2) (special tool #9340, SAE Fuel Pump Lock Ring Wrench).
Rotate the breaker bar (1) clockwise until all seven notches of the lock-ring (3) have engaged.

Fig 3: Fuel Supply, Return & Vapor Lines
Courtesy of CHRYSLER GROUP, LLC
Connect the fuel lines (1, 2) to the fuel pump module.
Connect the fuel tank vapor line (3) to the fuel pump module.

Fig 4: Access Cover, Connector & Screws
Courtesy of CHRYSLER GROUP, LLC
Connect the fuel pump module wire harness connector (4). Install the access cover and securely tighten the bolts.
Install the rear seat.
Connect the negative battery cable.
Use the Scan Tool to pressurize the system and check for leaks.