300M, Concorde, Intrepid, LHS, 1998-2004

Removal & Installation

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Pump Module-Left Side



  1. Release the fuel pressure.
  2.  
  3. Disconnect negative battery cable.
    NOTE
    The fuel level of the vehicle must be below 5/8 of a tank before you remove the module lock-rings. If it is above that you can spill fuel in the vehicle.

  4.  
  5. Drain partial fuel from fuel tank through the filler tube. Use a hard nylon tube, with a 30° cut on the end, to push the check valve open to drain fuel from tank.
  6.  
  7. Remove the rear lower seat cushion.
  8.  
  9. Push seat back and up to remove seat cushion.
  10.  
  11. Fold back the foam pad covering access cover for modules.
  12.  
  13. Disconnect the electrical connector from left side module.
  14.  
  15. Mark the module orientation.
  16.  
  17. Use special tool 9340 to remove left side module lock ring.
  18.  
  19. Drain fuel from left side of fuel tank. Lift module up enough to push hose into tank and drain. Do not spill fuel in interior of vehicle.
  20.  
  21. Disconnect the electrical connector for the left side fuel level card from bottom of the module top.
  22.  
  23. Disconnect the electrical connector for the right side fuel level sending card.
  24.  
  25. Lift module top half off and tip lower half on its side to drain remaining fuel from the reservoir.
  26.  
  27. Remove wire from module.
  28.  
  29. Use a screwdriver to separate the locking tabs on the level sending card.
  30.  
  31. Lift level sending card straight up and out of module.
  32.  
  33. Disconnect the electrical wiring from module.
  34.  
  35. Remove level sending card.
  36.  

To install:

  1. Install level sending card, make sure that the locking tabs are locked on the card.
  2.  
  3. Route wires in the proper location.
  4.  
  5. Install module top to module bottom.
  6.  
  7. Connect the electrical connectors for right side fuel level sending card, left side module card and fuel pump.
  8.  
  9. Install module and align marks on the module for proper orientation.
  10.  
  11. Install module lock-ring.
  12.  
  13. Use special tool #9340 to tighten left side module lock ring.
  14.  
  15. Connect the electrical connector to left side module and install plastic access cover.
  16.  
  17. Fold the foam pad covering access cover for modules back into place.
  18.  
  19. Install rear lower seat cushion
  20.  
  21. Rear lower seat cushion installed.
  22.  
  23. Fill fuel tank.
  24.  
  25. Connect negative battery cable.
  26.  
  27. Fill fuel tank. Use the scan tool to pressurize the fuel system. Check for leaks.
  28.  

Pump Module-Right Side



  1. Release the fuel pressure.
  2.  
  3. negative battery cable.
    NOTE
    The fuel level of the vehicle must be below 5/8 of a tank before you remove the module lock-rings. If it is above that you can spill fuel in the vehicle.

  4.  
  5. Drain partial fuel from fuel tank through the filler tube. Use a hard nylon tube, with a 30° cut on the end, to push the check valve open to drain fuel from tank.
  6.  
  7. Remove the rear lower seat cushion.
  8.  
  9. Push seat back and up to remove seat cushion.
  10.  
  11. Fold back the foam pad covering access cover for modules.
  12.  
  13. Disconnect the electrical connector from left side module.
  14.  
  15. Mark the module orientation.
  16.  
  17. Use special tool #9340 to remove left side module lock ring.
  18.  
  19. Drain fuel from left side of fuel tank. Lift module up enough to push hose into tank and drain. Do not spill fuel in interior of vehicle.
  20.  
  21. Lift module up and out of tank as far as possible.
  22.  
  23. Disconnect the electrical connector from the bottom of the left side module.
  24.  
  25. Lift module top half off and tip lower half on its side to drain remaining fuel from the reservoir.
  26.  
  27. Push in on the release tab on the fuel line fitting to release the fuel line from the fuel pump fitting.
  28.  
  29. Remove the Fuel supply line from the top of the bottom half of the module.
  30.  
  31. Fuel return line and Saipan return line . Just pull tube up to release from module.
  32.  
  33. Remove the fuel return and Siphon return hoses from the bottom module.
  34.  
  35. Remove plastic access covers from floor pan right side.
  36.  
  37. Disconnect the fuel supply line from module.
  38.  
  39. Mark the module orientation.
  40.  
  41. Use special tool #9340 to remove right side module lock ring.
  42.  
  43. Drain fuel from right side of fuel tank. Lift module up enough to push hose into tank and drain. Do not spill fuel in interior of vehicle.
  44.  
  45. Pull module up and out of fuel tank.
  46.  
  47. Unlatch the fuel level sending card from module.
  48.  
  49. Fuel level sending card released.
  50.  
  51. Remove the ground wire from the check valve and fuel pressure regulator.
  52.  
  53. Remove fuel level sending card from module.
  54.  
  55. Cut tie straps from hoses to remove wiring harness for fuel level card.
  56.  

To install:

  1. Install level sending card, make sure that the locking tabs are locked on the card.
  2.  
  3. Route wires in the proper location.
  4.  
  5. Tie strap the wires harness to the hoses.
  6.  
  7. Feed hoses and wiring harness into fuel tank and over the center hump in tank.
  8.  
  9. Install module and align marks on the module for proper orientation.
  10.  
  11. Install module lock-ring.
  12.  
  13. Use special tool #9340 to tighten right side module lock ring.
  14.  
  15. Connect the fuel supply line to module.
  16.  
  17. Install plastic access covers to floor pan right side.
  18.  
  19. Install the fuel return hoses to module.
  20.  
  21. Install fuel supply line to module.
    WARNING
    Make sure that wires are routed properly.


    WARNING
    Make sure that the level sending card wire is tie strapped to the fuel supply line at the module.

  22.  
  23. Install left side module top to module bottom.
  24.  
  25. Connect the electrical connectors for right side fuel level sending card, left side module card.
    WARNING
    Make sure that wires are routed properly.

  26.  
  27. Install module and align marks on the module for proper orientation.
  28.  
  29. Install module lock-ring.
  30.  
  31. Use special tool #9340 to tighten left side module lock ring.
  32.  
  33. Connect the electrical connector to left side module and install plastic access cover.
  34.  
  35. Fold the foam pad covering access cover for modules back into place.
  36.  
  37. Install rear lower seat cushion
  38.  
  39. Rear lower seat cushion installed.
  40.  
  41. Fill fuel tank.
  42.  
  43. Connect negative battery cable.
  44.  
  45. Fill fuel tank. Use the scan tool to pressurize the fuel system. Check for leaks.
  46.  

 
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