Module, Fuel Pump: Removal: Removal

WARNING:

Risk of injury to eyes and skin from contact with fuel. Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked and approved containers. Failure to follow these instructions may result in possible serious or fatal injury.

WARNING:

The fuel system is under constant high pressure even with engine OFF. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury.

Fig 1: Fuel Pump Module Connectors

Courtesy of CHRYSLER GROUP, LLC

Perform the fuel system pressure release procedure. Refer to FUEL DELIVERY, GAS, STANDARD PROCEDURE .
NOTE:
The fuel pump module has to be properly located in the fuel tank for the fuel level gauge to work properly.
Use a marker and place a mark (4) across the position of the fuel pump module lock-ring, fuel pump module (1) and the fuel tank prior to removal.
Remove the fuel line (3) from the fuel pump module.

Fig 2: Identifying Module Lock Ring Tool
Courtesy of CHRYSLER GROUP, LLC

NOTE:
Prior to removing the fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening.
Position the lock-ring remover/installer (special tool #9340, SAE Fuel Pump Lock Ring Wrench) into the notches on the outside edge of the lock-ring.
Install a 1/2 inch drive breaker bar into the lock-ring remover/installer (special tool #9340, SAE Fuel Pump Lock Ring Wrench).
Rotate the breaker bar counterclockwise and remove the lock-ring.

Fig 3: Main Fuel Pump Module
Courtesy of CHRYSLER GROUP, LLC

WARNING:
The fuel pump module reservoir does not empty out when the tank is drained. The fuel in the reservoir will spill out when the module is removed.

NOTE:
Do not spill fuel into the interior of the vehicle.
Raise the fuel pump module out of the fuel tank using caution not spill fuel inside the vehicle.

Fig 4: Draining Fuel
Courtesy of CHRYSLER GROUP, LLC
Tip the fuel pump module on its side and drain all fuel from the reservoir.

Fig 5: Fuel Pump Module
Courtesy of CHRYSLER GROUP, LLC
Remove the fuel pump module from the fuel tank using caution not to bend the float arm.

Fig 6: Fuel Pump Module O-Ring
Courtesy of CHRYSLER GROUP, LLC
Remove and discard the rubber O-ring seal.