Replacing Your Fuel Pump Control Module: Step-By-Step Guide

Replacing a fuel pump control module can be a straightforward task, depending on the make and model of your vehicle. In some cases, it may be necessary to remove the rear passenger seat or fold down the rear seat to access the module, which is typically located in the trunk or rear of the vehicle. The process generally involves disconnecting the negative battery cable, removing the old module by unplugging the electrical connector and removing any mounting hardware, and then installing the new module by securing it in place and reconnecting the electrical connector. In some instances, it may be necessary to perform a recalibration or programming of the new module. It is important to refer to the specific instructions for your vehicle and consult a qualified mechanic if you are unsure about the procedure.

Disconnecting and reconnecting the battery cables

Firstly, locate the battery in your vehicle. The battery is typically located in the engine bay, which can be accessed by lifting the hood of your car. Once you have identified the battery, the next step is to identify the battery cables. There are two types of battery cables: positive (+) and negative (-). The positive cable is usually red, while the negative cable is generally black. These cables are connected to the battery terminals, which are the metal posts protruding from the battery.

Now, it's time to disconnect the cables. Start by loosening the nut or bolt that secures the cable to the terminal using a wrench or socket. Be sure to disconnect the negative cable first. This is an important safety precaution as it helps prevent short circuits and potential electrical hazards. Once the negative cable is loose, carefully move it away from the terminal. After that, you can proceed to disconnect the positive cable by loosening the corresponding nut or bolt and removing the cable.

At this point, both battery cables should be disconnected. If you need to replace the battery or perform any maintenance on the cables themselves, now is the time to do so. Ensure that you have the necessary tools and replacement parts before proceeding.

To reconnect the battery cables, follow these steps in reverse. First, connect the positive cable to the positive terminal and tighten the nut or bolt securely. Then, connect the negative cable to the negative terminal and tighten it as well. Ensure that the connections are firm and secure before moving on.

Finally, you can close the hood of your car and start the engine to ensure that the battery is functioning properly. If your vehicle doesn't start, double-check the battery connections and ensure that they are secure and correct, paying attention to the polarity of the cables.

Checking for corrosion

Corrosion is a serious issue in a vehicle's fuel system and can lead to engine failure. It is a chemical process that converts metal to an oxide or other stable compounds, such as rust, and is accelerated by the presence of water. As such, it is important to check for corrosion when replacing a fuel pump control module.

Firstly, you will need to locate the fuel pump control module. Depending on the vehicle, it may be located on the rear Crossrail above the spare tire, on the rear frame wall, or near the fuel tank. Once located, you will need to disconnect the module wiring harness and inspect the circuits of the connection for any signs of corrosion or connection issues.

If you find corrosion, it is important to clean or replace any affected parts to prevent further damage. You should also consider using corrosion-resistant products to help protect against future corrosion. For example, some fuel pump driver modules are engineered with a powder coat for high corrosion resistance and longer-lasting durability. Additionally, rubber mounts can be used to position the module away from the steel frame, increasing protection from corrosion and damage to the metal housing.

It is also important to check for corrosion in other parts of the fuel system, as it can damage other metal components such as fuel injectors or carburetor jets. Contamination of the fuel system with solid particles due to corrosion can lead to fuel pump failure, hard or long start conditions, rough idle, and failure to start.

Replacing the mounting bolts

To replace the mounting bolts, start by lowering the spare tire. Once the tire is lowered, the fuel pump driver module is easily accessible underneath the vehicle. Depending on your car model, the fuel pump driver module is located either on the rear Crossrail above the spare tire or on the rear frame wall.

Next, squeeze the locking tab and remove the electrical connector using a 13-millimetre socket wrench. Remove the mounting nuts on both sides and take out the old module. Then, take the mounting bolts and capped rubber standoffs and place the mounting bolts through the module's mounting holes. After that, slide the capped rubber standoffs over the bolts. Align the module to its original position and screw the bolts until the rubber standoffs are compressed and the module is secure. Finally, reattach the electrical connector, and the installation process is complete.

Reattaching the electrical connector

Firstly, ensure that the fuel pump driver module is securely in place. Check that the mounting bolts have been tightened and the rubber standoffs are compressed. This will ensure that the module is firmly held in its original position.

Next, you can proceed to reattach the electrical connector. This step may vary depending on your vehicle's specific application, but it typically involves plugging the connector back into the fuel pump driver module. Use a 13-millimeter socket wrench to secure the connection. Make sure the locking tab is engaged to prevent accidental disconnection.

Once the electrical connector is securely attached, you can move on to any remaining steps in the installation process. This may include reconnecting the battery or performing any necessary calibrations. Always refer to your vehicle's specific repair manual or seek advice from a qualified mechanic if you are unsure about any steps.

It is important to note that some vehicles may have slight variations in the reattachment process, so it is always best to consult a repair manual specific to your vehicle's make and model for detailed instructions.

Checking the ground on the FPCM

To check the ground on the FPCM, you will need to locate the FPCM itself. In a 2004 E350, for example, the Fuel Pump Driver Module (FPDM) is located on the frame rail on the driver's side forward of the rear axle. Once you have located the FPCM, you can check the circuits of the connection for any signs of corrosion or connection issues.

Next, you will need to check for power to the FPCM. This can be done by checking the white wire, which should be supplied with power from the fuel pump through the inertia switch when the ignition switch is in the run position.

After confirming power to the FPCM, you can check the ground by verifying that the black/orange wire of the FPCM has a good ground connection. This can typically be done by connecting a jumper wire from the black/orange wire to a known good ground source.

If the FPCM is not grounded properly, you may need to clean or replace the ground wire or connection. In some cases, you may need to add an additional ground wire to ensure a proper ground connection.

It is important to note that working on fuel system components can be dangerous, and it is always recommended to consult a qualified mechanic or technician if you are unsure about any part of the process.

Frequently asked questions