Fuel Pump Module: Removal

The fuel pump module is divide 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.

This vehicle may or may not be equipped with an access plate. This plate is located on floorpan inside vehicle at rear cargo area. If not equipped with an access plate, the fuel tank must first be lowered to gain access to fuel pump module. 

Fig 1: Removing Access Plate

Courtesy of DAIMLERCHRYSLER CORP.

If equipped with an access plate, fuel tank removal will not be necessary for fuel pump module removal. Access is from rear cargo area. 

1. Four cargo hold down 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.
3. Remove 4 fuel pump module access plate nuts.
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 STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE .
7. Disconnect 2 fuel lines at fuel pump module by pressing on 2 buttons at sides of fitting.
   Fig 2: Identifying Top Of Fuel Pump Module

   Courtesy of DAIMLERCHRYSLER CORP.
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
9. Disconnect ORVR hose clamp and hose at pump module fitting.
10. Remove module lock ring using a brass drift and hammer (counterclockwise).
11. Carefully lift upper section of pump module from fuel tank exposing connections (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.
       Fig 3: Disconnecting Fuel Pressure Regulator/Sending Unit Electrical Connector

       Courtesy of DAIMLERCHRYSLER CORP.
    2. Disconnect fuel pressure regulator at bottom of upper pump module section. Press on 2 locking tabs.
    3. Disconnect fuel return line at bottom of upper pump module section. Press on 2 locking tabs.
    4. Remove upper section of pump module from fuel tank.
       Fig 4: Removing Upper Section - Fuel Pump Module

       Courtesy of DAIMLERCHRYSLER CORP.
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.
       Fig 5: Removing Lower Section - Fuel Pump Module

       Courtesy of DAIMLERCHRYSLER CORP.
    2. The sides of pump module are equipped with tension springs. These springs hold module to bottom of fuel tank into 2 formed guides. Release module assembly from these 2 guides by sliding towards right side of fuel tank.
       Fig 6: Identifying Fuel Pump Module Guides (In Fuel Tank)

       Courtesy of DAIMLERCHRYSLER CORP.
    3. Lift assembly from fuel tank.