Fuel pump and fuel level sending unit module – removal and installation

Warning: Gasoline is extremely flammable, so take extra precautions when you work on any part of the fuel system.

1. The fuel pump/fuel level sending unit module includes the fuel filter/fuel pressure regulator, the electric fuel pump assembly (including the fuel pump inlet filter) and the fuel level sending unit. This section covers the removal and installation of the complete mod­ule, which is removed as a complete assem­bly. None of the components can be replaced separately; if any part fails, the entire assem­bly must be replaced.

2. Relieve the fuel system pressure (Fuel pressure relief procedure).

3. Disconnect the cable from the negative battery terminal (see Engine electrical systems).

4. Raise the vehicle and place it securely on jackstands.

5. Remove the fuel tank (Fuel tank – removal and installation).

6. To prevent dirt from entering the fuel tank, clean the area surrounding the fuel pump/fuel level sending unit.

7. Mark the position of the arrow on the fuel pump module so the new one can be installed in the same orientation.

8. Using a pair of large pliers to turn the lock-ring, or using a hammer and a brass drift (see illustration) to tap on the lock-ring, turn it counterclockwise. When the lock-ring is loose, unscrew it. Carefully remove the fuel pump/fuel level sending unit module from the tank (see illustration).

7.8a Use a large pair of pliers or a hammer and drift to loosen the lock-ring that secures the fuel pump/fuel level sending unit module

RAM Trucks Fuel and exhaust systems - gasoline engines Use a large pair of pliers or a hammer and drift to loosen the lock-ring that secures the fuel pump/fuel level sending unit module

7.8b Carefully remove the fuel pump/fuel level sending unit module from the fuel tank. Inspect the large rubber gasket that seals the mounting hole for the pump/sending unit

RAM Trucks Fuel and exhaust systems - gasoline engines Carefully remove the fuel pump/fuel level sending unit module from the fuel tank. Inspect the large rubber gasket that seals the mounting hole for the pump/sending unit

9. Inspect the large rubber gasket (see illustration 7.8b). If it’s cracked, torn, deterio­rated or otherwise damaged, replace it.

10. When installing the fuel pump/fuel level sending unit module, rotate the module until the embossed alignment arrow on the module is aligned properly (see illustration).

7.10 When installing the fuel pump/fuel level sending unit module, make sure the alignment arrow on top of the module is aligned with the center mark of the three hash marks on top of the fuel tank

RAM Trucks Fuel and exhaust systems - gasoline engines When installing the fuel pump/fuel level sending unit module, make sure the alignment arrow on top of the module is aligned with the center mark of the three hash marks on top of the fuel tank

11. Installation is otherwise the reverse of removal.