🔧 Town & Country - Fuel Pump Replacement

The fuel pump on your Town & Country is an in-tank pump module (it sits inside the fuel tank). Replacement involves safely relieving fuel pressure, disconnecting the electrical connector and fuel lines, then removing the lock ring to lift the module out and install a new seal.

Difficulty Level: Advanced | Estimated Time: 3-6 hours

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⚠️ Safety & Precautions

• 🧯 Work outdoors or in a very well-ventilated area; fuel vapors are extremely flammable.
• 🔥 No smoking, no sparks, no hot work lights; use an LED work light.
• 🧤 Wear safety glasses and fuel-resistant gloves; fuel can spray when lines are opened.
• 🔋 Disconnect the negative battery cable before opening the fuel system.
• 🧱 Support the vehicle securely on jack stands if you must drop the tank; never rely on a floor jack alone.

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🔧 Required Tools

You'll need the following tools for this repair:

• Safety glasses
• Nitrile gloves
• Fire extinguisher Class B
• LED work light
• 10mm socket
• 13mm socket
• 15mm socket
• 3/8" drive ratchet
• 6" socket extension
• Torque wrench 10-200 Nm
• Flat trim tool
• Flathead screwdriver
• Fuel line disconnect tool set (specialty)
• Fuel pump lock ring removal tool (specialty)
• Brass drift punch
• Rubber mallet
• Floor jack (rated 3-ton minimum)
• Jack stands (rated 3-ton minimum)
• Wheel chocks
• Drain pan
• Shop towels

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Fuel pump module assembly - Qty: 1
• Fuel pump module tank seal O-ring - Qty: 1
• Fuel pump lock ring - Qty: 1

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📋 Before You Begin

• 🅿️ Park on level ground, set the parking brake, and chock the rear wheels using wheel chocks.
• ⛽ Try to run the fuel level low (under 1/4 tank). A lighter tank is safer and easier to handle.
• 🔋 Disconnect the battery: use a 10mm socket to remove the negative battery cable and tuck it aside so it can’t spring back.
• 🧠 Assumption: Some Town & Country vans have a service access panel above the fuel tank; if yours does not, you’ll follow the “drop the tank” path below.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Relieve fuel pressure

• Remove the fuel cap to release vapor pressure.
• Open the under-hood fuse/relay box and remove the fuel pump relay (use the flathead screwdriver carefully if needed).
• Start the engine and let it run until it stalls; crank 2-3 more seconds to bleed off remaining pressure.

Step 2: Choose your access method

• Method A (top access panel): You’ll open a floor access cover inside the van, then remove the pump from above.
• Method B (drop the tank): You’ll lower the fuel tank to reach the pump module.

Step 3A: Method A - Open the in-cabin access panel

• Move or fold seats as needed to expose the carpeted floor area over the tank.
• Use a flat trim tool to lift trim/carpeting carefully.
• Remove the access cover fasteners using a 10mm socket or flathead screwdriver (fastener type varies).
• Clean the area around the pump module with shop towels so dirt doesn’t fall into the tank.

Step 3B: Method B - Raise vehicle and support the fuel tank

• Lift the rear of the van with a floor jack (rated 3-ton minimum) and support with jack stands (rated 3-ton minimum).
• Place a drain pan under the tank area and keep shop towels ready.
• Support the fuel tank with the floor jack (use a wide piece of wood if available to spread the load).
• Disconnect the filler neck and vent connections as needed using flathead screwdriver (hose clamps) and flat trim tool (clips).
• Disconnect electrical connectors near the tank using a flat trim tool (press tab, pull straight).
• Remove fuel tank strap bolts with a 15mm socket.
• Lower the tank slightly with the floor jack and disconnect remaining lines using a fuel line disconnect tool set (specialty).
• Lower the tank enough to access the top of the pump module.

Step 4: Disconnect fuel lines and electrical connector at the pump

• Unplug the pump electrical connector by hand; use a flat trim tool if the lock tab is stubborn.
• Disconnect the fuel supply/return/EVAP quick-connect lines using the fuel line disconnect tool set (specialty).
• Tip: Wrap the connection with a towel first.

Step 5: Remove the fuel pump lock ring

• Mark the pump module orientation to the tank using a flathead screwdriver (light scratch mark) so you reinstall the same way.
• Use a fuel pump lock ring removal tool (specialty) to loosen and remove the lock ring.
• If you don’t have the ring tool, use a brass drift punch and rubber mallet to tap the ring counterclockwise. (A brass drift is a non-steel punch to reduce spark risk.)

Step 6: Remove the fuel pump module

• Lift the module straight up carefully. Angle it as needed to clear the float arm (the float measures fuel level).
• Let fuel drain off the module into the tank; keep the drain pan below for drips.
• Remove the old seal O-ring from the tank opening using a flat trim tool.

Step 7: Install the new seal and pump module

• Install the new tank seal O-ring, making sure it sits flat and is not twisted.
• Lower the new pump module into the tank in the same orientation as your marks.
• Install the lock ring and tighten using the fuel pump lock ring removal tool (specialty).
• Torque to 55 Nm (41 ft-lbs) using a torque wrench 10-200 Nm (with the correct adapter for your lock ring tool).

Step 8: Reconnect lines and wiring

• Reconnect fuel and vapor lines until you feel/hear a solid click.
• Reconnect the electrical connector fully (ensure the lock tab engages).

Step 9A: Method A - Reinstall access panel

• Reinstall the access cover and fasteners using a 10mm socket or flathead screwdriver.
• Torque to 3 Nm (27 in-lbs) if using bolts with a torque wrench 10-200 Nm.
• Reinstall carpet/trim using the flat trim tool.

Step 9B: Method B - Reinstall fuel tank

• Raise the tank with the floor jack (rated 3-ton minimum) and reconnect any remaining lines using the fuel line disconnect tool set (specialty) as needed.
• Reinstall tank straps and tighten strap bolts using a 15mm socket.
• Torque to 68 Nm (50 ft-lbs) using a torque wrench 10-200 Nm.
• Reconnect filler neck/vent hoses using a flathead screwdriver for clamps.
• Lower the vehicle off the jack stands (rated 3-ton minimum).

Step 10: Restore power and prime the fuel system

• Reinstall the fuel pump relay.
• Reconnect the negative battery cable using a 10mm socket.
• Turn the key to RUN (do not start) for 3 seconds, then OFF for 5 seconds; repeat 3-4 times to prime the system.

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✅ After Repair

• ✅ Start the engine and let it idle for 1-2 minutes.
• 🧻 Inspect for leaks at the pump top and at every quick-connect while the engine is running (use shop towels to spot wetness).
• 🚗 Road test for 10 minutes, then re-check for leaks.
• 🛠️ If a check engine light appears, scan the codes (fuel/EVAP codes usually mean a connector or line isn’t fully seated).

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💰 DIY vs Shop Cost

Shop Cost: $900-$1,600 (parts + labor)

DIY Cost: $250-$650 (parts only)

You Save: $650-$950 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 3-6 hours.

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🎯 Ready to get started?

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