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Removal And Installation: 4X4: Removal

WARNING:

The fuel system is under constant pressure even with engine off. Until the fuel pressure has been properly relieved from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Wear protective clothing and eye protection. Make sure the area in which the vehicle is being serviced is in a well ventilated area.

  1. Perform the draining fuel tank procedure. Refer to FUEL DELIVERY, STANDARD PROCEDURE .
  2. Disconnect and isolate the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), disconnect the IBS connector first before disconnecting the negative battery cable.
  3. Remove the rear seat cushion. Refer to SEAT CUSHION, REMOVAL AND INSTALLATION .
    GC0164830Courtesy of CHRYSLER GROUP, LLC
  4. Lift the cover, unscrew the screws and remove the access cover to the fuel pump (1).
    GC0162995Courtesy of CHRYSLER GROUP, LLC
  5. Disconnect the electrical connection (1) of the electric pump fuel.
  6. Disconnect the fuel vapor quick connect couplings (3).
  7. Disconnect the quick coupling of the fuel delivery pipe (2).
    GC0165038Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Prior to removing the fuel pump module, use compressed air to remove any accumulated dirt and debris from around the fuel tank opening.

  8. Position the (special tool #9340, SAE Fuel Pump Lock Ring Wrench) (1a) into the notches on the outside edge of the lock-ring (1b).
  9. Rotate the wrench counterclockwise and remove the lock-ring (1b).
    GC0165293Courtesy of CHRYSLER GROUP, LLC
  10. Raise the fuel pump assembly.
  11. Disconnect the quick coupling of the fuel vapor recovery pipe (1).
    GC0165245Courtesy 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.

  12. Lift up and remove the fuel pump module (1) out of the fuel tank using caution not to bend the float arm.
    GC0164111Courtesy of CHRYSLER GROUP, LLC
  13. Remove the seal ring (1) from the tank.

INSTALLATION 

  1. Install a new seal ring on the tank.
    GC0165293Courtesy of CHRYSLER GROUP, LLC
  2. Connect the quick coupling of the fuel vapor recovery pipe (1).
    GC0164383Courtesy of CHRYSLER GROUP, LLC
  3. Install the fuel pump assembly, taking care to align the reference (1a) on the tank with the appendix (1b) of the pump.
    GC0165518Courtesy of CHRYSLER GROUP, LLC
  4. Install the fuel pump assembly mounting ring, by aligning the reference (1a) with the reference (1b) on the tank.
  5. Position the (special tool #9340, SAE Fuel Pump Lock Ring Wrench) into the notches on the outside edge of the lock-ring and tighten the fuel pump assembly lock ring.
    GC0162995Courtesy of CHRYSLER GROUP, LLC
  6. Connect the fuel vapor quick couplings (3).
  7. Connect the quick coupling of fuel supply hose (2).
  8. Connect the fuel pump's electrical connection (1).
  9. Connect the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), connect the IBS connector.
  10. Use the Scan Tool to operate the fuel pump and check for leaks.
    GC0164830Courtesy of CHRYSLER GROUP, LLC
  11. Install the access cover for the fuel pump and securely tighten the screws (1).
  12. Install the rear seat cushion. Refer to SEAT CUSHION, REMOVAL AND INSTALLATION .
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