Fuel Pump: Service and Repair

FUEL PUMP MODULE

Lock Ring Wrench:

Special Tool(s)







Removal and Installation

WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.
- Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel causing personal injury or a fire hazard.

All Vehicles
1. Drain the fuel tank.
2. Release the fuel system pressure.
3. Disconnect the battery ground cable.

Five Hundred, Montego







4. Remove the rear lower seat cushion.
- Release the latches and pull upward on the rear lower seat cushion and remove.

Freestyle
5. Position the second row seats rearward.
6. Remove the rear seat latching brackets.
- Remove the latching bracket bolts.
- Remove the latching brackets.
- To install, tighten to 17 Nm (13 lb-ft).

All vehicles
7. Remove the fuel pump module access cover.
8. Clean the surrounding area of the fuel pump module mounting flange and the quick connect couplings with compressed air.
9. Disconnect the fuel pump module electrical connector.
10. Disconnect the fuel supply tube-to-fuel pump module quick connect coupling.
11. Disconnect the fuel vapor tube-to-fuel pump module quick connect coupling from the top of the fuel pump module.







12. Install the special tool and remove the fuel pump module lock ring.
13. Carefully lift the fuel pump module out of the fuel tank allowing access to disconnect the quick connect couplings.
14. Disconnect the fuel supply tube-to-fuel pump module quick connect coupling.
15. Disconnect the fuel vapor tube-to-fuel pump module quick connect coupling.

16. CAUTION:
- The fuel pump module must be handled carefully to avoid damage to the float arm.
- Place absorbant pads on the floor pan in case of spills. Carefully remove fuel pump module from the fuel tank to avoid fuel spillage inside the vehicle.

Completely remove the fuel pump module from the fuel tank.

17. CAUTION:
- Inspect the surfaces of the fuel pump module flange and fuel tank O-ring seal contact surfaces. Do not polish or adjust the O-ring seal contact area of the fuel tank flange or the fuel tank. Install a new fuel pump module or fuel tank if the O-ring seal contact area is bent, scratched or corroded.
- Make sure to install a new fuel pump module O-ring seal and lock ring.

NOTE: To install, apply clean engine oil to the O-ring seal.

Remove the fuel pump module O-ring seal.

18. To install, reverse the removal procedure.
- Make sure the alignment arrows on the fuel pump module and the fuel tank meet before tightening the fuel pump module lock ring.