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Fuel Pump Module: Removal

  1. Release fuel system pressure. Refer to STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE PROCEDURE  .
  2. Remove the battery cover and disconnect negative battery cable.
  3. Remove the convertible top fasteners (15 nuts) (Fig 1 ) and (Fig 2 ).
    Fig 1: Removing Convertible Top Attachment
    G02682104Courtesy of DAIMLERCHRYSLER CORP.
    Fig 2: Removing Convertible Fastener
    G02682105Courtesy of DAIMLERCHRYSLER CORP.
  4. Lift the top up and disconnect the heated back glass electrical connector (Fig 3 ) from both sides of the glass.
    Fig 3: Disconnecting Back Glass Electrical Connector
    G02682106Courtesy of DAIMLERCHRYSLER CORP.
  5. Pull top forward and out of the way.
  6. Roll deck lid carpet forward and out of the way.
    7. NOTE: Be careful the sealer on the cover will make it difficult to remove the cover.
    Fig 4: Removing Fuel Pump Module Cover
    G02682107Courtesy of DAIMLERCHRYSLER CORP.
    Fig 5: Removing Of Cover And Rivets
    G02682108Courtesy of DAIMLERCHRYSLER CORP.
  7. Remove the 4 rivets from the fuel pump module cover (Fig 4 ) and (Fig 5 ). You may have to knock out the center pin with a punch.
  8. Using a scraper or long knife cut the sealer under the cover to remove it from the vehicle.
  9. Remove the foam block from the top of the fuel pump module (Fig 6 ) and (Fig 7 ).
    Fig 6: Removing Pump Module Foam Block
    G02682109Courtesy of DAIMLERCHRYSLER CORP.
    Fig 7: Removing Foam Block
    G02682110Courtesy of DAIMLERCHRYSLER CORP.
  10. Unlock and disconnect the electrical connector from the fuel pump module.
  11. Clean the area round the fuel pump module.
  12. Mark fuel pump module location on tank.
  13. Disconnect the fuel line, wrap shop towels around ends of fuel supply line (Fig 8 ).
    Fig 8: Disconnecting Electrical & Fuel Connection
    G02682111Courtesy of DAIMLERCHRYSLER CORP.
  14. Use Special Tool #6856 to remove fuel pump module locknut (Fig 9 ).
    Fig 9: Removing Fuel Pump Module Lock Ring
    G02682112Courtesy of DAIMLERCHRYSLER CORP.
  15. Lift module up to remove being careful not to spill the residual fuel that is left in it. The float arm of the level sensor catches on the inside of the fuel tank while removing the module. Tilt the module assembly to one side while removing it. Discard old seal.
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