Fuel Pump Module: Removal

WARNING: This page is about a different car, the 2008 Dodge Sprinter. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: To prevent damage to the float rod, the float and float rod must be removed from the pump module. This step must be done before the pump module is removed from the fuel tank.

Drain and remove fuel tank.
Thoroughly clean area around pump module at top of tank.
Disconnect all fuel lines from pump module fittings.

The plastic fuel pump module lock nut (lock ring) is threaded onto fuel tank. Install Special Tool #6856 to lock nut and remove lock nut. The fuel pump module will spring up slightly after lock nut is removed.

Fig 1: Fuel Pump Module R/I

Courtesy of CHRYSLER LLC

1 - LOCK NUT (LOCK RING)

2 - SPECIAL TOOL #6856

3 - TOP OF PUMP MODULE

Pull module assembly up just a few inches to gain access to float support arm/rod (3). Be careful not to bend float support rod while removing pump module.

Fig 2: Float Rod Clip

Courtesy of CHRYSLER LLC

1 - FUEL LEVEL SENSOR

2 - CLIP

3 - FLOAT ROD

Rotate clip (2) to release float rod (3) from fuel level sensor (1).

Fig 3: Removing/Installing Float Rod Clip

Courtesy of CHRYSLER LLC

1 - FUEL LEVEL SENSOR

2 - CLIP

3 - FLOAT ROD

Twist rod (3) slightly to remove from fuel level sensor. Do not allow float assembly to fall into fuel tank.

Fig 4: Removing/Installing Float Rod Clip

Courtesy of CHRYSLER LLC

1 - FUEL LEVEL SENSOR

2 - CLIP

3 - FLOAT ROD

While holding float rod, remove fuel pump module from fuel tank.
Remove float assembly from fuel tank.
Remove and discard rubber gasket (seal) from pump module.