Fuel Pump Module Replacement

WARNING: This page is about a different car, the 2005 Dodge Stratus and 2005 Chrysler Sebring. However, it is still accessible from the selected car via links, so may be relevant.

Remove the rear seat cushion. (Refer to - REAR SEAT .)
Remove the protector.
Bleed the residual pressure from inside the fuel pipe line to prevent the fuel from spraying out. [Refer to On-vehicle Service - FUEL PUMP CONNECTOR DISCONNECTION (HOW TO REDUCE PRESSURIZED FUEL LINE .)] < 2.4L ENGINE > or [Refer to On-vehicle Service - FUEL PUMP CONNECTOR DISCONNECTION (HOW TO REDUCE PRESSURIZED FUEL LINE .)] < 3.0L ENGINE >

Fig 1: Removing Protector
Courtesy of DAIMLERCHRYSLER CORPORATION
Disconnect the hose and connector connections, and then use special tool MB991480 to remove the fuel pump module.

Fig 2: Removing Fuel Pump Module
Courtesy of DAIMLERCHRYSLER CORPORATION

CAUTION: Install the packing to the fuel tank, and then install the fuel pump module to the fuel tank. Installing the packing to the fuel pump module will damage the packing lip when installing the fuel pump module to the fuel tank, and fuel leakage will occur.
Check that the fuel tank is not damaged or deformed, and then securely install the packing to the fuel tank.
NOTE: If the packing is damaged or deformed, replace with new packing.
CAUTION:
- Do not tilt the fuel pump module when installing.
- The packing should not be folded over as shown by "A" in the illustration.
Apply soap water to the inside of the packing, and then install the fuel pump module.

Fig 3: Identifying Correct Way Of Packing Installation To Fuel Tank
Courtesy of DAIMLERCHRYSLER CORPORATION

CAUTION: When tightening, be careful not to let the fuel pump module turn together with the cap. If the mating marks are misaligned, the float may measure a remaining amount of fuel in correctly, causing the low fuel warning light to malfunction.
Use special tool MB991480 to align the mating marks on the fuel tank and fuel pump module, and tighten the cap to the specified torque.
Tightening torque: 80 +/- 10 N.m (59 +/- 7 ft-lb)
Check for leaks from the installation section of the fuel pump module by the following procedure.
1. Apply soapy water to the inside diameter of the cap.
2. Choke the vapor hose and main hose, apply an internal pressure of 10 kPa (1.45 psi) or less from the return hose and check that no bubbles form in the soapy water.
Connect the connector, and then install the protector.
Install the rear seat cushion. (Refer to - REAR SEAT .)

Fig 4: Aligning Mating Marks On Fuel Tank And Fuel Pump Module
Courtesy of DAIMLERCHRYSLER CORPORATION