Fuel Pump Module: Removal

The fuel pump module is divided into 2 sections, upper and lower. To service the check (control) valve, replace only the upper section. To service the fuel gauge sending unit, remove the upper section. To service the electric fuel pump, fuel pressure regulator or primary inlet filter, remove both sections and replace lower section.

Fuel tank removal will not be necessary for fuel pump module removal. Access is from rear cargo area. 

1. Four cargo holdown clamps are located inside the vehicle on the floor of the rear cargo area. Remove the 2 rearward mounted clamps by drilling out the clamp rivets.
2. Fold carpeting forward to gain access to fuel pump module access plate. See Fig 1.
3. Remove 4 fuel pump module access plate nuts. See Fig 1.
4. While applying heat from a heat gun, carefully pry up fuel pump module access plate. Take care not to bend plate.
5. Thoroughly clean area around top of pump module to prevent contaminants from entering fuel tank or fuel lines.
   WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE EVEN WITH ENGINE OFF. BEFORE SERVICING THE FUEL PUMP MODULE, FUEL SYSTEM PRESSURE MUST BE RELEASED.
6. Release fuel system pressure. Refer to PRESSURE RELEASE .
7. Disconnect 2 fuel lines at fuel pump module, by pressing on 2 buttons at sides of fitting. See Figure.
8. Disconnect electrical connector at top of fuel pump module by sliding red colored tab first to unlock, and push grey colored tab down for removal. See Figure.
9. Disconnect ORVR hose clamp and hose at pump module fitting. See Figure.
10. Remove module lockring using a brass drift and hammer (counter-clockwise). See Figure.
11. Carefully lift upper section of pump module from fuel tank exposing connections. See Figure.(Lift upper section from tank very slowly until rubber gasket can be retained. If not, gasket will fall into fuel tank.) 
    1. Disconnect electrical connector at bottom of upper pump module section. See Figure.
    2. Disconnect fuel pressure regulator at bottom of upper pump module section. See Figure. Press on 2 locking tabs.
    3. Disconnect fuel return line at bottom of upper pump module section. See Figure. Press on 2 locking tabs.
    4. Remove upper section of pump module from fuel tank. See Figure.
12. Using an approved gas holding tank, drain fuel tank through pump module opening. If check (control) valve, or, only upper section of pump module is being serviced, tank draining is not necessary. If any other fuel pump module component is being serviced, the tank must be completely drained to the bottom. 
13. To remove lower section of pump module from fuel tank:
    1. Using finger pressure, push on plastic release tab while sliding lock tab upward. See Figure.
    2. The sides of pump module are equipped with tension springs. See Figure. These springs hold module to bottom of fuel tank into 2 formed guides. See Figure. Release module assembly from these 2 guides by sliding toward right side of fuel tank.
    3. Lift assembly from fuel tank.
    Fig 1: Removing Access Plate

    Courtesy of DAIMLERCHRYSLER CORP.