This procedure removes and replaces the fuel pump module in the diesel fuel tank, including depressurizing the fuel system, accessing the tank, and replacing the module assembly.

Warnings

Tools required

Parts

• Fuel pump module assembly × 1 — Use OEM specification (Mopar 68210743AA or equivalent)
• Fuel pump lock ring seal/gasket × 1 — Usually included with pump module
• Fuel line O-rings (multiple sizes) × 1 — Use OEM specification
• Tank strap hardware (if corroded) × 1 — Use OEM specification

Preparation

1. Park vehicle on level, well-ventilated surface away from ignition sources and traffic
2. Disconnect both negative and positive battery cables to eliminate all electrical power (negative first, then positive)
3. Allow vehicle to sit for minimum 2 hours after last operation to allow fuel system pressure to drop
4. Relieve fuel system pressure: Remove fuel fill cap to vent tank pressure
5. Raise vehicle using appropriate lift or jack and support securely on jack stands rated for vehicle weight at frame rails
6. Place fuel-rated drip pans under tank and work area
7. Clean all dirt and debris from top of fuel tank and surrounding area to prevent contamination
8. Prepare clean work area for fuel pump module - lay out clean shop towels on clean surface
9. If tank is more than 1/4 full, consider using approved fuel transfer pump to drain fuel into approved containers

Procedure

1. 1

   Access fuel tank area
   From under the vehicle, inspect the fuel tank location between the frame rails behind the cab. Remove the rubber access cover or skid plate if equipped. The fuel pump module is accessed from the top of the tank. On crew cab models, the spare tire may need to be lowered for access clearance. Remove the spare tire if it interferes with tank removal.
2. 2

   Disconnect electrical connector
   Locate the fuel pump module electrical connector on top of the tank. Squeeze the locking tabs and carefully disconnect the electrical connector. Inspect connector terminals for corrosion or damage. Secure the harness out of the way using a zip tie or hook to prevent damage during tank removal.
   ⚠Plastic connector tabs are brittle - do not force. Apply gentle pressure while squeezing release tabs.
3. 3

   Disconnect fuel supply and return lines
   Identify the fuel supply line (larger diameter) and return line connections at the fuel pump module. Place shop towels around connections to catch residual fuel. Using appropriate fuel line disconnect tools, disconnect both fuel lines from the module. Cap or plug the open fuel lines immediately to prevent contamination. Expect residual fuel spillage - direct into drip pan.
   ⚠Even with system depressurized, residual fuel will drain from lines. Have towels and drip pan ready.
4. 4

   Disconnect EVAP and vent lines
   Locate and disconnect any EVAP vent lines or vapor lines connected to the top of the fuel pump module. These are typically smaller diameter plastic lines with push-to-connect fittings. Use appropriate disconnect tools and mark line positions if necessary for reinstallation. Inspect lines for cracks or damage.
5. 5

   Support fuel tank
   Position a transmission jack or suitable floor jack with a wide wood block under the center of the fuel tank. Raise jack until it just contacts the tank and supports the weight, but does not lift the vehicle. Secure the tank to the jack with a strap or chain to prevent it from shifting during strap removal.
   ⚠️Fuel tank weighs 200+ lbs when partially full. Ensure jack is rated for load and tank is securely positioned before removing straps.
6. 6

   Remove tank mounting straps
   Locate the two fuel tank mounting straps that wrap around the tank. Using appropriate socket, remove the bolts securing the rear of each strap to the frame crossmember. The straps will pivot down once the rear bolts are removed. Lower the tank slowly using the jack (approximately 4-6 inches) while guiding the straps away. Verify all electrical connections and fuel lines are disconnected before lowering further.
   ⚠Lower tank slowly and check frequently for any missed connections that could be damaged by lowering.
   Torque spec

   Mounting Bolts37 Nm (27 lb-ft)
7. 7

   Remove fuel pump module lock ring
   With tank lowered for access, clean the entire area around the fuel pump module lock ring thoroughly to prevent any contamination. Using the fuel pump lock ring tool (or carefully with a brass punch and hammer if tool unavailable), rotate the lock ring counterclockwise to unthread it. The lock ring has multiple tabs - engage tool securely before applying force. Remove the lock ring completely and set aside on clean surface.
   ⚠CRITICAL: Do not allow ANY dirt or debris to fall into the tank opening during this step. Cover tank opening immediately if contamination occurs.
   ⚠Never use steel tools that could create sparks. Use brass punch or proper plastic lock ring tool only.
8. 8

   Remove fuel pump module assembly
   Carefully lift the fuel pump module straight up and out of the tank opening. The module has a float arm and fuel level sender that extends downward - angle the module carefully to avoid bending the float arm or damaging the fuel level sender. Once clear of the opening, tilt to drain residual fuel back into tank. Place the old module on shop towels in drip pan. Immediately cover the tank opening with clean shop towels to prevent contamination.
   ⚠Float arm and fuel level sender are delicate. Do not bend or force the module during removal.
   ⚠Keep tank opening covered at all times when module is removed to prevent debris entry.
9. 9

   Inspect tank and clean sealing surface
   With the module removed and opening still covered, inspect visible interior of tank for debris, contamination, or water. Remove and inspect the old seal/gasket from the tank flange. Using clean, lint-free shop towels, thoroughly clean the tank flange sealing surface where the module seats. Remove all old gasket material, dirt, and debris. The surface must be perfectly clean for proper seal.
   ⚠Do not allow cleaning debris or towel fibers to fall into tank. Work carefully and keep opening covered when not actively cleaning.
10. 10

    Prepare new fuel pump module
    Unpack new fuel pump module and inspect for shipping damage. Install new seal/gasket onto the module flange - ensure it seats properly in the groove. Install new O-rings on all fuel line fittings (supply, return, and vent connections). Lightly lubricate O-rings with clean diesel fuel. Verify the fuel level sender float arm moves freely and is not bent. Compare new module to old module to verify correct replacement part.
    ℹ️New O-rings are critical for leak-free operation. Never reuse old O-rings on fuel connections.
11. 11

    Install new fuel pump module
    Carefully lower the new fuel pump module into the tank opening, angling as necessary to clear the float arm and sender. Align the module with the tank opening and orientation marks if present. Press the module down firmly and evenly to seat the gasket against the tank flange. Verify the module is fully seated and the gasket is not pinched or displaced.
    ⚠Ensure gasket remains properly positioned during installation. A displaced gasket will cause fuel leaks.
12. 12

    Install and torque lock ring
    Position the lock ring over the fuel pump module and engage the threads. Using the lock ring tool, rotate clockwise to thread the ring onto the tank. Tighten the lock ring to the specified torque in a cross pattern if multiple tabs are present, or progressively around the ring to ensure even sealing. Verify the module does not rotate as the lock ring is tightened.
    ⚠Lock ring torque is critical for proper seal. Use calibrated torque wrench and proper tool engagement.
    Torque spec

    Fuel Pump Lock Ring92 Nm (68 lb-ft)
13. 13

    Raise and secure fuel tank
    Using the jack, carefully raise the fuel tank back into position between the frame rails. Guide the tank into place while ensuring no wires or lines are pinched. Align the tank mounting strap holes with the frame mounting points. Install tank mounting straps and insert bolts. Torque the mounting strap bolts to specification.
    ⚠Verify all lines and wiring are clear of tank straps before tightening. Pinched lines will cause leaks or electrical issues.
    Torque spec

    Mounting Bolts37 Nm (27 lb-ft)
14. 14

    Reconnect fuel lines
    Install the fuel supply line (larger) and return line to the appropriate fittings on the fuel pump module. Push the quick-connect fittings straight onto the module connections until they click and lock. Verify each connection is secure by pulling gently on the line - it should not come off. If threaded fittings are used instead of quick-connects, torque to specification using new O-rings.
    ⚠Ensure quick-connect fittings are fully engaged and locked. Partially connected lines will leak under pressure.
    Torque spec

    Fuel Line Fittings25 Nm (18 lb-ft)
15. 15

    Reconnect EVAP, electrical, and final connections
    Reconnect any EVAP vent lines or vapor lines to the module, ensuring each connection clicks into place. Connect the electrical connector to the fuel pump module - it should lock with an audible click. Verify the connector is fully seated and locking tab is engaged. Reinstall any access covers or skid plates that were removed. Raise and reinstall spare tire if it was removed.
    Torque spec

    Access Cover Screws5 Nm (4 lb-ft)

Reassembly

1. Reconnect battery cables (positive first, then negative)
2. Before starting engine, cycle ignition key to ON position (without cranking) 3-4 times, waiting 5 seconds between cycles, to prime fuel system
3. Inspect all fuel connections around fuel pump module for leaks during priming cycles
4. Lower vehicle from jack stands

Verification

• With vehicle still elevated and engine off, inspect all fuel line connections at the module for any signs of fuel seepage or drips
• Start engine and allow it to idle - listen for normal fuel pump operation (no unusual noises or surging)
• With engine running, use inspection mirror to carefully examine all fuel connections from below for any active leaks
• Verify fuel gauge reads correctly and changes appropriately as fuel is consumed
• Monitor for any fuel odors inside or outside vehicle during first several drives
• Check for diagnostic trouble codes related to fuel system - none should be present
• Road test vehicle under various load conditions to verify normal fuel delivery and no surging or hesitation

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