Fuel Pump Module: Installation

WARNING: This page is about a different car, the 2004 Dodge Sprinter. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: Whenever the fuel pump module is serviced, the rubber gasket must be replaced.

Thoroughly clean locknut (lockring) and lock-nut threads at top of tank.
Position new gasket (seal) to fuel tank opening.
Position float rod assembly partially into fuel tank.
Position fuel pump module partially into fuel tank.
Twist rod (3) (Fig 1 ) into clip (2) on fuel level sensor (1).

Fig 1: Installing Float Rod
Courtesy of DAIMLERCHRYSLER CORP.
Rotate clip (2) (Fig 2 ) to attach rod (3) to clip.
After attaching float assembly to fuel level sensor, carefully position fuel pump module into opening in fuel tank.
Position locknut over top of fuel pump module. Install locknut finger tight.

Fig 2: Installing Float Rod Clip
Courtesy of DAIMLERCHRYSLER CORP.
Both fuel line fittings should be pointed to the right side of the vehicle. Rotate and position alignment arrow (Fig 3 ) towards right side of vehicle (if necessary) before tightening locknut. This step must be performed to prevent the module's float from contacting the side of fuel tank.

Fig 3: Aligning Pump Module In Fuel Tank
Courtesy of DAIMLERCHRYSLER CORP.
Tighten locknut using Special Tool #6856. Refer to TORQUE SPECIFICATIONS table.
Install fuel tank. Refer to REMOVAL /INSTALLATION .