D. Fuel Pump Module Replacement
NOTE:The fuel pump module has an upper and lower section. Only the lower section will be replaced.
1. Use the following procedure to release the fuel system pressure:
a. Remove the fuel pump relay from the Power Distribution Center (PDC). For location of the relay, refer to the label on the underside of the PDC cover.
b. Start and ruin the engine until it stalls.
c. Attempt to restart the engine until it will no longer run.
d. Turn the ignition key to the "OFF" position.
e. Install the fuel pump relay into the PDC.
f. Loosen the gas cap.
2. Disconnect the negative battery cable.
3. There are four hold-down clamps located inside the vehicle on the floor of the rear cargo area. Remove the two (2) rearward mounted clamps by drilling out the clamp rivets on each hold-down (Figure 3).
NOTE:
Fuel tank removal will not be necessary for fuel pump module removal. Access the module through an access plate located in the rear cargo area.
4. Vacuum the rear cargo area carpet to remove any metal chips created while drilling out the rivets.
5. Fold the carpeting forward to gain access to the fuel pump module access plate.
6. Using a heat gun, heat the area around the fuel pump module access plate nuts and then chip away the sealant to gain access to the four (4) retaining nuts
7. Remove the four (4) fuel pump module access plate nuts (Figure 4).
8. While using a heat gun, carefully pry up the fuel pump module access plate (Figure 4).
CAUTION:
Use of excessive force to remove the cover may cause it to bend.
9. Thoroughly clean the area around the top of the pump module to prevent contaminants from entering the fuel tank (Figure 5). Also clean the floor pan of any loose sealant chips.
WARNING:
The fuel system is under constant pressure even with the engine off. Fuel system pressure must be released before servicing the fuel pump module.
10. Disconnect the electrical connector on the top of the fuel pump module by sliding the red colored tab first to unlock, and then pushing the gray colored tab down to disconnect it (Figure 5).
11. Disconnect the ORVR hose from the pump module fitting (Figure 5).
12. Disconnect the two (2) fuel lines from the fuel pump module (Figure 5).
13. Using a brass drift and hammer, turn the module lock ring counter-clockwise (Figure 5).
14. Carefully lift the upper section of the pump module from the fuel tank exposing the fuel and electrical connections (Figure 6).
CAUTION:
To prevent the module gasket from falling into the gas tank, lift the upper section from the tank very slowly until the rubber gasket can be retained.
15. Use the following procedure to remove the upper section of the pump module.
a. Disconnect the electrical connector from the bottom of the upper pump module section (Figure 6).
b. Press on the two (2) quick connect locking tabs to disconnect the fuel pressure regulator from the bottom of the upper pump module section (Figure 6).
c. Press on the two (2) locking tabs to disconnect the fuel supply line from the bottom of the upper pump module section (Figure 6).
d. Remove the upper section of the pump module from the fuel tank (Figure 7).
16. Using an approved gasoline holding tank, drain the fuel tank completely through the pump module opening.
17. Remove the lower section of the pump module from the fuel tank:
a. Reach into the tank module opening and using finger pressure, push on the plastic release tab while sliding the lock tab upward. (Figure 8)
b. The sides of the pump module are equipped with tension springs (Figure 8). These springs hold the module to the bottom of the fuel tank into two (2) formed guides. Release the module assembly from these two (2) guides by sliding it towards the right side (passenger side) of the fuel tank.
c. Lift the lower pump module assembly from the fuel tank.
18. Transfer the fuel level sending unit and wiring harness to the new fuel pump module.
19. Position the new lower section of the fuel pump module assembly into the fuel tank.
20. The bottom of the fuel tank has two (2) formed guides. Lock the new module assembly into these two (2) guides by sliding the module towards the left side (driver's side) of the tank.
21. Push down on the plastic release and lock tab to lock the module into the fuel tank guides (Figure 8).
22. Place the new upper module seal into position.
23. Connect the fuel supply line to the bottom of the upper pump module section (Figure 6).
24. Connect the fuel pressure regulator to the bottom of the upper pump module section (Figure 6).
25. Connect the electrical connector to the bottom of the upper pump module section (Figure 6).
26. Position the upper pump module onto the fuel tank. The alignment notch must be facing rear of the tank (Figure 5).
27. Position the lock ring onto the module. Using a brass drift and hammer, tap the lock ring (clockwise) until it rotates up to the built-in stops (Figure 5).
28. Attach the two fuel lines to the top of the fuel pump module (Figure 5).
29. Connect the ORVR hose to the pump module fitting (Figure 5).
30. Connect the electrical connector on the top of the fuel pump module. Then slide the red color tab to lock the connector.
31. Remove the fuel pressure transducer and adapter.
32. Return the fuel that was removed from the fuel tank and reinstall the gas cap.
33 Connect the negative battery cable.
34. Start the engine and check for fuel leaks underhood and at the fuel pump module.
35. Apply silicone sealant (Mopar P/N 04883971 or equivalent) to the edge of the fuel pump module access opening.
36. Install the fuel pump module access plate and four nuts (Figure 4). Tighten the nuts to 26 in. lbs. (3 N.m).
37. Position the carpet and install two cargo clamp rivets into each cargo hold-down clamps.
38. For vehicles equipped with a 2.4 liter engine, clear all diagnostic trouble codes from all modules.
NOTE:
Erase any trouble codes in the PCM only after all other modules have had their trouble codes erased.
39. For vehicles registered in California, continue with Section L - Complete Proof of Correction Form for California Residents.