Pacifica, 2003-2005

Fuel Pump

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Removal & Installation



The in-tank fuel pump module contains the fuel pump and pressure regulator which adjusts fuel system pressure. Fuel pump voltage is supplied through the fuel pump relay.

The fuel pump is serviced as part of the fuel pump module. The fuel pump module is installed in the top of the fuel tank and contains the electric fuel pump, fuel pump reservoir, inlet strainer fuel gauge sending unit, fuel supply and return line connections and the pressure regulator. The inlet strainer, fuel pressure regulator and level sensor are the only serviceable items. If the fuel pump requires service, replace the fuel pump module.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     

  6.  
  7. Fold the drivers side rear seat and tilt it forward.

    Two bolts for the rear seat
     
    Seat electrical connection
     
    Seat
     
    Rear console scuff plate
     
    Rear console electrical connector
     
    Fourteen screws retaining the rear console
     
    Screws from the cup holder pockets
     
    Screw from the console pocket under the rubber mat
     
    Left rear door sill plate
     

  8.  
  9. Cut the carpet along the mounting bracket for the center console. The cut does not need to exceed a foot in length. Pull the carpet back to access the pump cover.
  10.  
  11. Cut the seal for the pump access panel and remove the cover. Clean the sealer from the floor pan and cover. Use a vacuum cleaner to remove any debris before removing the pump lockring.

    Click image to see an enlarged view

    Fig. Remove the rear console scuff plate-2003-04 models

    Remove the rear console scuff plate-2003-04 models

    Click image to see an enlarged view

    Fig. Remove the rear console assembly-2003-04 models

    Remove the rear console assembly-2003-04 models

    Click image to see an enlarged view

    Fig. Remove the screws from the cup holder pockets-2003-04 models

    Remove the screws from the cup holder pockets-2003-04 models

    Click image to see an enlarged view

    Fig. Remove the screws from under the rubber mat in the console pocket-2003-04 models

    Remove the screws from under the rubber mat in the console pocket-2003-04 models

    Click image to see an enlarged view

    Fig. Cut the carpet where indicated (dotted line), no longer than a foot in length-2003-04 models

    Cut the carpet where indicated (dotted line), no longer than a foot in length-2003-04 models

    Click image to see an enlarged view

    Fig. Cut the seal for the pump access cover-2003-04 models

    Cut the seal for the pump access cover-2003-04 models

    Click image to see an enlarged view

    Fig. Clean the sealer from the cover contact surfaces-2003-04 models

    Clean the sealer from the cover contact surfaces-2003-04 models
  12.  
  13. Remove or disconnect the following:

    Vapor line and electrical connection
     
    Pump lockring using a brass punch
     
    Pump top
     

  14.  
  15. Drain the fuel tank.

    Electrical connections from the bottom of the pump top and the passenger side level sensor assembly
     
    Tabs attaching the return and supply lines
     
    Return line from the pump using a small prytool to pry the tab back and tip the hose to one side, then pry the tab on the other side to release the hose
     
    Fuel supply line from the top of the pump in the same manner as the return line
     
    Fuel pump
     

  16.  

To install:

  1. Install or connect the following:

    Fuel pump
     
    Fuel supply line and return lines
     
    Electrical connections to the bottom of the pump
     
    Pump top, gasket and lockring

    Click image to see an enlarged view

    Fig. Pump lockring contact points, place the brass punch at these locations when removing/installing the ring-all models

    Pump lockring contact points, place the brass punch at these locations when removing/installing the ring-all models
     
    Fuel line and electrical connection
     
    Negative battery cable
     

  2.  
  3. Fill the fuel tank.
  4.  
  5. Use a DRB III to pressurize the fuel system and check for leaks. If no leaks detected, disconnect the negative battery cable.
  6.  
  7. Clean the access cover and floorpan.
  8.  
  9. Apply sealer to the outer edge of the access plate and the push pin holes.

    Click image to see an enlarged view

    Fig. Apply sealer to the outer edge of the access plate and the push pin holes-2003-04 models

    Apply sealer to the outer edge of the access plate and the push pin holes-2003-04 models
  10.  
  11. Install or connect the following:

    Access cover and the push pins into the holes
     
    Carpet and left rear door sill plate
     
    Screws to the console pocket under the rubber mat
     
    Screws to the cup holder pockets
     
    Fourteen screws retaining the rear console
     
    Rear console electrical connector
     
    Rear console scuff plate
     
    Seat
     
    Seat electrical connection
     
    Two bolts for the rear seat
     
    Negative battery cable
     

  12.  

 
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