This procedure involves removing the fuel tank to access and replace the in-tank fuel pump module on a 2014 Ram 2500 with 6.7L Cummins diesel engine.

Warnings

Tools required

Parts

• Fuel pump module assembly × 1 — Use OEM Mopar specification
• Fuel tank O-ring seal × 1 — Use OEM specification
• Fuel line quick connect seals × 1 — Replace if damaged

Preparation

1. Ensure fuel tank is less than 1/4 full. If necessary, drain excess fuel into approved fuel storage containers using a transfer pump.
2. Park vehicle on level ground in a well-ventilated area away from ignition sources. Engage parking brake and chock rear wheels.
3. Disconnect negative battery cable and isolate to prevent accidental electrical sparks.
4. Allow exhaust system to cool completely (minimum 2 hours after operation) to prevent ignition of fuel vapors.
5. Raise vehicle and support securely on jack stands rated for vehicle weight. Ensure adequate working clearance beneath vehicle.
6. Place drain pans beneath fuel tank area to catch any fuel spillage.
7. Have fire extinguisher readily accessible before beginning work.

Procedure

1. 1

   Relieve fuel system pressure
   Remove the fuel pump relay from the Power Distribution Center (PDC) located in the engine compartment. Attempt to start the engine and allow it to run until it stalls. Attempt to restart 2-3 times to ensure all residual pressure is released. Turn ignition to OFF position.
   ⚠️Even with relay removed, some fuel pressure may remain. Wear safety glasses and have towels ready when disconnecting fuel lines.
2. 2

   Disconnect fuel filler tube and vent lines
   Locate the fuel filler neck at the left rear of the vehicle. Loosen the hose clamp securing the filler tube to the tank inlet. Disconnect the filler tube by pulling it away from the tank. Disconnect the EVAP vent line from the top of the tank by pressing the quick-connect release tab.
3. 3

   Disconnect fuel supply and return lines
   Locate the fuel supply and return lines on the driver side of the fuel tank. Using the appropriate quick-connect tool, press the release mechanism and pull the lines straight off the tank fittings. Cap or plug the lines immediately to prevent contamination and fuel spillage.
   ⚠Fuel will drain from lines. Have rags and drain pan positioned to catch spillage.
4. 4

   Disconnect electrical connector
   Locate the fuel pump module electrical connector on top of the tank (accessible from driver side). Press the red safety tab and disconnect the electrical connector from the fuel pump module. Secure the connector away from the tank to prevent damage during removal.
5. 5

   Support fuel tank
   Position a transmission jack or suitable tank support device under the center of the fuel tank. Raise the jack until it just contacts the tank, providing support but not lifting the tank. Ensure the tank is stable and well-balanced on the jack.
   ⚠The tank must be properly balanced on the support. An unbalanced tank can fall when straps are removed, causing injury.
6. 6

   Remove tank strap bolts
   Locate the two fuel tank strap bolts at the rear of each tank strap (total of 4 bolts for 2 straps). Using a socket and ratchet, remove all four tank strap bolts. Carefully lower the straps away from the tank while maintaining support with the transmission jack.
   Torque spec

   Tank Strap Bolts35 Nm (26 lb-ft)
7. 7

   Lower and remove fuel tank
   Slowly and carefully lower the fuel tank using the transmission jack. As you lower the tank, ensure no lines, wires, or hoses are still connected. Once fully lowered, slide the tank out from under the vehicle. Place the tank on a clean work surface away from ignition sources.
   ⚠Even a partially full tank is very heavy. Use caution when maneuvering. Get assistance if needed.
8. 8

   Clean fuel pump access area
   Thoroughly clean the top surface of the fuel tank around the fuel pump module lock ring. Remove all dirt, debris, and corrosion to prevent contamination from entering the tank during pump removal. Use compressed air and a clean cloth.
   ⚠Any debris that falls into the tank can damage the new fuel pump or contaminate the fuel system.
9. 9

   Remove fuel pump lock ring
   Using the fuel pump lock ring tool, rotate the lock ring counterclockwise to loosen. The lock ring may require significant force to break free initially. Once loose, unscrew the lock ring completely and remove it from the tank opening.
   ⚠Do not use impact tools or strike the lock ring tool with a hammer as this can create sparks or damage the module.
10. 10

    Remove fuel pump module
    Carefully lift the fuel pump module straight up and out of the tank opening. Tilt the module slightly to navigate the fuel level float arm through the opening. Be aware that fuel will drain from the module reservoir. Allow fuel to drain back into the tank, then remove the module completely. Remove and inspect the O-ring seal on the tank opening.
    ⚠Do not damage the fuel level sender float arm during removal or fuel gauge will read incorrectly.
11. 11

    Install new fuel pump module
    Install a new O-ring seal in the groove on the fuel tank opening. Lightly lubricate the O-ring with clean diesel fuel. Carefully insert the new fuel pump module into the tank opening, guiding the fuel level float arm through without damage. Ensure the module is fully seated and the orientation marks align with the tank.
12. 12

    Install and torque lock ring
    Place the lock ring onto the fuel pump module and hand-thread it clockwise until it is finger-tight. Using the lock ring tool and torque wrench, tighten the lock ring to the specified torque. Verify the module does not rotate during final tightening.
    ⚠Proper torque is critical to ensure fuel seal integrity and prevent leaks. Over-torque can damage the tank threads.
13. 13

    Reinstall fuel tank
    Position the fuel tank on the transmission jack and carefully raise it into position under the vehicle. Align the tank with the mounting points and reconnect the electrical connector to the fuel pump module. Install the tank straps and hand-start all four strap bolts before final tightening.
    Torque spec

    Tank Strap Bolts35 Nm (26 lb-ft)
14. 14

    Reconnect fuel lines and filler tube
    Reconnect the fuel supply and return lines to the tank fittings, pushing firmly until an audible click is heard confirming proper engagement. Tug gently on each line to verify secure connection. Reconnect the EVAP vent line. Reconnect the fuel filler tube and secure with the hose clamp.
    ⚠Ensure quick-connect fittings are fully engaged. Improper connection will cause fuel leaks and potential fire hazard.
15. 15

    Prime fuel system and check for leaks
    Reinstall the fuel pump relay in the PDC. Reconnect the negative battery cable. Turn the ignition key to the RUN position (do not start) for 5 seconds, then OFF. Repeat this cycle 3-4 times to allow the fuel pump to prime the system. Inspect all fuel connections for leaks. Start the engine and allow it to idle while carefully inspecting all fuel connections, the tank, and the pump module area for any signs of fuel leakage.
    ⚠️If any fuel leaks are detected, immediately shut off the engine and repair the leak before proceeding. Do not operate the vehicle with fuel leaks present.

Reassembly

1. Torque all fasteners to specifications using a calibrated torque wrench.
2. Ensure all quick-connect fuel fittings are fully engaged and locked.
3. Verify electrical connector to fuel pump module is fully seated with locking tab engaged.
4. Double-check that no tools or rags were left in the work area or on top of the fuel tank.

Verification

• Turn ignition to RUN position multiple times and listen for fuel pump operation (should run for 2-3 seconds each cycle).
• Start engine and verify it runs smoothly without hesitation or stalling.
• Check fuel gauge operation - it should read accurately and respond to fuel level.
• Perform a thorough inspection under the vehicle for any fuel leaks at the tank, straps, lines, and connections while engine is running.
• After test drive, re-inspect all connections for leaks and verify no fuel odor is present.
• Scan for diagnostic trouble codes - there should be no fuel system related codes present.

More procedures for this vehicle