Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2009 Freightliner Sprinter 2500 V6-3.0L DSL TurboFACTORY OEM SERVICE PROCEDURE
Fuel Pump Module - Installation
INSTALLATION
CAUTION: Whenever the fuel pump module is serviced, the rubber gasket must be replaced.
1. Thoroughly clean locknut (lockring) and locknut threads at top of tank.
2. Position new gasket (seal) to fuel tank opening.
3. Position float rod assembly partially into fuel tank.
4. Position fuel pump module partially into fuel tank.
5. Twist rod (3) into clip (2) on fuel level sensor (1).
6. Rotate clip (2) to attach rod (3) to clip.
7. After attaching float assembly to fuel level sensor, carefully position fuel pump module into opening in fuel tank.
8. Position locknut over top of fuel pump module. Install locknut finger tight.
9. The fuel line fittings should be pointed to the right side of the vehicle. Rotate and position alignment arrow towards right side of vehicle (if necessary) before tightening locknut. This step must be performed to prevent the module's float from contacting the side of fuel tank.
10. Tighten locknut using the Spanner Wrench 6856. Refer to Torque Specifications.
11. Install fuel tank.
Factory Service Tools
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.