Pacifica 2006-2008

Fuel Pump

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Drain the fuel tank.
  8.  
  9. Disconnect the exhaust system between the catalytic converter and the muffler.
  10.  
  11. Support the exhaust system with jack stands.
  12.  
  13. Remove muffler hanger rubber grommets and the center exhaust hanger rubber grommets.
  14.  
  15. Remove the rear portion of the exhaust system.
  16.  
  17. Disconnect the fuel tank electrical connector.
  18.  
  19. Disconnect the fuel line and EVAP line.
  20.  
  21. Disconnect the vapor recirculation tube.
  22.  
  23. Mark the driveshaft rear connection and disconnect the driveshaft rear connection.
  24.  
  25. Remove the driveshaft support/bearing.
  26.  
  27. Support the driveshaft with a jack.
  28.  
  29. Remove the left rear tire and splash shield.
  30.  
  31. Remove the fuel filler tube from the rubber hose at fuel tank.
  32.  
  33. Support the fuel tank with a transmission jack.
  34.  
  35. Remove the 2 fuel tank straps and lower fuel tank.
  36.  
  37. Drain any remaining fuel from the tank and remove the tank.
  38.  
  39. Clean around the fuel pump module lockring prior to removal.
  40.  
  41. Disconnect the vapor line and electrical connector.
  42.  
  43. Remove the fuel pump module lockring using a brass punch to remove the 1 / 4 turn lockring.
  44.  
  45. Remove fuel pump module top.
  46.  
  47. Disconnect electrical connector.
  48.  
  49. Disconnect the wire connector to the passenger side level sensor before removing the reservoir from the tank.
  50.  
  51. Remove the return line from pump module. Use a suitable tool to pry the tab back and tip the hose to one side. Pry the tab on other side back to release the hose.
    CAUTION
    Care should be taken to not crack/break the locking tabs or supply line fitting.

  52.  
  53. Remove the fuel line from the top of the pump module. Use a small screwdriver to pry the tab back and tip hose to one side. Pry the tab on the other side back to release the hose.
  54.  
  55. Tip fuel pump module on its side to remove the fuel from the reservoir.
  56.  
  57. Remove the fuel pump module.
  58.  

To install:

  1. Install the fuel pump module into the fuel tank.
  2.  
  3. Connect the siphon and fuel lines to fuel pump module.
  4.  
  5. Connect the fuel pump electrical connector to the bottom of the module top.
  6.  
  7. Connect the wire connector to the passenger side level sensor.
  8.  
  9. Install the fuel pump module top to the module.
  10.  
  11. Install the fuel pump module gasket and lockring. Use a brass punch to install the 1 / 4 turn lockring.
  12.  
  13. Connect the vapor line and electrical connector.
  14.  
  15. Support the fuel tank with a transmission jack.
  16.  
  17. Raise fuel tank and install in the vehicle.
  18.  
  19. Install the 2 fuel tank straps.
  20.  
  21. Install the remaining components in the reverse order of removal.
  22.  
  23. Connect the negative battery cable.
  24.  
  25. Fill the fuel tank and use the DRBIII® scan tool to pressurize the fuel system. Check for leaks.
  26.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the fuel cap.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. Drain the fuel tank.
  10.  
  11. Remove the exhaust system, from the resonator back.
  12.  
  13. If equipped with AWD mark the driveshaft rear connection and remove it (driveshaft).
  14.  
  15. Disconnect the fuel pump electrical connector from the chassis connector.
  16.  
  17. Disconnect the vapor canister line at the right front of the fuel tank.
  18.  
  19. Disconnect the fuel supply line. Disconnect the EVAP vapor line.
  20.  
  21. Disconnect the fuel vapor recirculation line at the right rear of the fuel tank.
  22.  
  23. Loosen the clamp and remove the fuel fill hose from the fuel tank.
    NOTE
    Properly support the fuel tank, with a transmission/transaxle jack or equivalent. Use retaining straps to secure the fuel tank to the jack. Failure to properly support and secure the tank during removal may cause fuel to spill or the tank to fall from the jack.

  24.  
  25. Remove the fuel tank retaining strap bolts and straps.
  26.  
  27. Lower the tank.
  28.  
  29. Disconnect and remove all necessary lines and hoses from the tank.
  30.  
  31. Remove the tank from the vehicle.
    NOTE
    Clean the area around the fuel pump, prior to removal. Failure to clean this area may cause dirt to get into the fuel system causing damage to the fuel system and/or engine.

  32.  
  33. Disconnect all lines and electrical connections.
  34.  
  35. Remove the fuel pump module lockring using a brass punch to remove the 1 / 4 turn lockring.
  36.  
  37. Remove the module lock ring. Remove the module top.
  38.  
  39. Drain the fuel from the tank using approved siphoning equipment.
    NOTE
    The wire connector to the passenger side level sensor needs to be disconnected before removing the reservoir from the tank.

  40.  
  41. Remove the return line from the pump, using a suitable tool.
  42.  
  43. Remove the fuel line from the top of the pump.
  44.  
  45. Tip the pump module on its side to remove fuel from the reservoir.
  46.  
  47. Remove the fuel pump module.
  48.  

To install:

  1. Installation is the reverse of the removal procedure.
    NOTE
    The fuel pump module top and bottom need to be correctly installed in order for the fuel level to be on the correct side of the fuel tank. If installed incorrectly, the fuel level arm will not be in the correct position inside the fuel tank and cause inaccurate fuel level readings.


    NOTE
    Make sure that all fuel line hoses are connected properly. Failure to connect fuel lines properly may result in a fuel leak.

  2.  
  3. Fill the fuel tank and use the DRBIII® scan tool to pressurize the fuel system.
  4.  
  5. Start the engine and check for leaks. Correct as required.
  6.  

 
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