Fuel pump replacement on a 2008 Chrysler Town & Country with the 3.8L gasoline V6 may be needed after confirmed low fuel delivery causes long cranking, a crank/no-start, stalling or loss of power. An inaccurate fuel gauge can point to the module’s sender. Relevant diagnostic examples include P0627 (fuel-pump control circuit) and P0461, P0462 and P0463 (fuel-level sensor performance or circuit faults). These symptoms and codes do not prove the pump has failed: check fuel pressure, electrical supply, wiring and sender operation before buying a replacement.
Application overview
The repair below uses the 2008 Town & Country 3.8L gasoline configuration as its worked example. The featured module is also cataloged for the specific Chrysler, Dodge and Volkswagen combinations in the compatibility table. That purchasing coverage does not make every connector, diagnostic test or fastener specification universal. Match the VIN, fuel type and original module reference before ordering.
Advanced DIY; fuel-tank removal and safe fuel handling
About 3–5 hours after diagnosis; allow longer for corrosion or tank cleaning
About $80–$160 for an aftermarket module; planning estimate, not a live listing price
Work with a cool exhaust in a well-ventilated area away from flames, heaters, smoking, sparks and equipment that can ignite vapor. Keep a suitable flammable-liquid fire extinguisher accessible. Relieve line pressure before opening a fitting, contain residual fuel, and disconnect battery negative before disassembly. Do not use a household vacuum to clean an open fuel tank.
Support the van on rated stands or a vehicle lift, and separately support and restrain the tank on a suitable jack/cradle. Keep its weight off the hoses and wiring. Do not cut an access hole, drill the tank, hammer a steel screwdriver against the retaining ring, or work under a vehicle held only by a jack. Stop for a leak, damaged tank mounting, unstable support or a connector that cannot be released without damage.
Featured replacement fuel-pump module
Brand: A-Premium. Product: one electric in-tank fuel-pump module with sending unit. ASIN: B07GZN8F8J. Amazon-listed part number: APFP0285AM; the matching manufacturer catalog family is APFP0285. The listing describes a pump, seal ring, sender and strainer; the manufacturer also confirms the float and gasket and lists no pressure sensor included. A new retaining ring is not listed as an included component.
Reference numbers include 68030875AA, 68030875AB and 68030875AD. These help identify the module family but do not replace a vehicle-fitment check. This is the gasoline application shown below; do not select it for a flex-fuel or later 3.6L van simply because the tank looks similar.
View fuel-pump module with sending unit
Vehicle compatibility
| Make | Model | Model years | Engine | Restriction |
|---|---|---|---|---|
| Chrysler | Town & Country | 2008 only | 3.3L V6 | Gasoline only |
| Chrysler | Town & Country | 2008–2010 | 3.8L V6 | Gasoline only; 2008 is the worked repair |
| Chrysler | Town & Country | 2008–2010 | 4.0L V6 | Gasoline only |
| Dodge | Grand Caravan | 2008–2010 | 3.8L V6 | Gasoline only |
| Dodge | Grand Caravan | 2008–2010 | 4.0L V6 | Gasoline only |
| Volkswagen | Routan | 2009–2010 | 3.8L V6 | Gasoline only |
| Volkswagen | Routan | 2009–2010 | 4.0L V6 | Gasoline only |
The 3.3L row is limited to the 2008 Town & Country gasoline application. It does not include the 3.3L Grand Caravan or 2009–2010 Town & Country. Confirm fuel type from the vehicle identification/emissions information and ask the supplier to match the VIN and original module. See the A-Premium application catalog.
Symptoms, fault codes and diagnostic checks
| Symptom or code | What to check before replacing the module |
|---|---|
| Long crank, no-start or stalling | Confirm actual fuel level, battery condition, pump command, power and ground. Check pressure with the correct sealed adapter; sound alone does not establish adequate fuel delivery. |
| P0627 — fuel-pump control circuit | Inspect the control wiring and connections between the PCM and TIPM. This can be an upstream electrical problem even when the symptom resembles a dead pump. |
| P0461 — fuel-level sensor 1 performance | Check for a sticking/bent float, tank damage and wiring faults. The sender’s movement and signal must change appropriately. |
| P0462 / P0463 — fuel-level sensor circuit low / high | These describe electrical signal conditions, not an empty or full tank. Inspect sender wiring and connectors before condemning the module. |
| Lean or misfire symptoms | Check ignition, air leaks, injectors and mechanical condition as well as fuel supply. A module will not correct every rough-running complaint. |
On this platform the pump is controlled through the Totally Integrated Power Module (TIPM). Do not assume there is a removable relay to swap. A loaded power-and-ground test is more useful than finding battery voltage on an unplugged connector. Use proper terminal probes; oversized meter probes can spread terminals and create heat-producing resistance. Delphi explains why voltage drop can imitate pump failure.
For the 2008 Town & Country 3.8L, the cited factory pressure procedure specifies 407 ± 34 kPa (59 ± 5 psi). It uses a fuel-line adapter selected for the connection: factory 6539 for a 5/16-inch line or 6631 for a 3/8-inch line. This is a test specification for that configuration, not a pressure adjustment for the new pump. If pressure is low, evaluate electrical supply and restrictions; if pressure falls after shutdown, isolate pump-side leakage from injector leakage using the proper test equipment. Do not pinch hard/plastic lines with ordinary pliers.
Tools, parts and supplies
The exact products below match the described tools. Buy only what you need, and check existing equipment first. The general hand tools are separate from the tank-support arrangement and diagnostic adapters; arrange those before opening the system.
| Tool or Supply | Exact Product | Product Link | Purpose and Selection Check |
|---|---|---|---|
| Metric sockets and ratchet | TEKTON SKT15311, 73-piece, 3/8-inch-drive 6-point socket and ratchet set | View TEKTON socket set | Includes shallow/deep 6–24 mm metric sockets and extensions. Match the actual bolt and hose-clamp heads; do not assume one socket size fits every fastener. |
| Torque wrench | LEXIVON LX-182, 3/8-inch drive, 10–80 lb-ft (13.6–108.5 N·m) | View 3/8-inch torque wrench | Covers the 55 N·m tank-strap and canister-bracket specification for the worked vehicle. Use a correctly fitting socket and do not use it to loosen bolts. |
| Floor jack | ARCAN A20003, 3-ton low-profile steel floor jack | View 3-ton floor jack | Raise at approved vehicle lift points. Confirm capacity, saddle contact and clearance. A hydraulic jack alone must never support the vehicle while you work underneath. |
| Vehicle stands | BIG RED T43002A, double-locking 3-ton jack stands, one pair | View double-locking jack stands | The 3-ton rating applies to the pair. Use the correct support points on hard, level ground. Confirm working height before committing to tank removal. |
| Wheel chocks | MaxxHaul 70472 solid-rubber wheel chocks, two-pack | View rubber wheel chocks | Restrain wheels that remain on the ground. Each chock is 8 × 4 × 6 inches; use an arrangement suited to the vehicle and surface. |
| Module retaining-ring wrench | OTC 6599 fuel-tank lock-ring wrench | View OTC lock-ring wrench | OTC lists 2004-and-newer Chrysler/Dodge minivans. Confirm full engagement on the ring. It requires a separate 1/2-inch drive; it does not establish Routan tool fitment. |
| Drive for the ring wrench | TEKTON SBH00224, 1/2-inch-drive × 24-inch breaker bar | View 1/2-inch breaker bar | Supplies the drive required by the OTC wrench. Use controlled hand force; do not strike or use an impact wrench on the fuel module. |
| Quick-connect release, conditional | Lisle 37000 six-piece fuel-line disconnect set | View fuel-line disconnect set | Includes 5/16- and 3/8-inch sizes among six tools. Use only on a coupling designed for this release style; many plastic safety-lock fittings release by their own tabs. |
| Gasoline container | Scepter FSCG552 SmartControl red gasoline container, 5 gallons | View 5-gallon gasoline container | Use enough approved containers for the fuel actually removed. Keep them closed when not transferring. An oil-drain pan is not a substitute for gasoline storage. |
| Manual fuel transfer, conditional | TERA PUMP TRDP14 manual siphon | View gasoline-compatible hand siphon | Manufacturer lists gasoline compatibility. Its short inlet suits accessible liquid/container transfer; do not force it through the vehicle filler neck or assume it bypasses anti-siphon hardware. |
| Eye protection | DEWALT DPG82 Concealer clear safety goggles, one pair | View clear safety goggles | Protect eyes when disconnecting lines and handling the module. Check the purchased package for the splash protection needed for the work. |
| Chemical-resistant gloves | Ansell Sol-Vex 37-185/9 nitrile gloves, large/size 9, one pair | View long-cuff nitrile gloves | Use the correct fit and chemical-compatibility guidance. Replace contaminated or damaged gloves; no glove should be treated as unlimited gasoline-immersion protection. |
| Clean shop wipes | Scott 75190 blue shop towels, one box of 200 | View boxed shop towels | For wiping external fittings and containing small residual drips. Keep loose fibers out of the tank and seal groove; these are not a gasoline-storage container. |
| Fuel-spill absorbent | New Pig MAT415 oil-only absorbent pads, 50-pack, 15 × 20 inches | View fuel/oil absorbent pads | Manufacturer lists fuel and oil absorption. Keep ready for drips, remove fuel-soaked material from the work area safely, and follow disposal instructions. |
| Tank cradle, conditional mount | 911 Motorsports JA240F four-point adapter, with floor-jack base | View four-point tank-support adapter | Requires a compatible M24 × 1.5 saddle mount; do not assume it mates to the listed Arcan jack. Check the 800 lb maximum, contact geometry and added 6–12 inches of height against actual lift clearance. Jack and retaining strap are separate. |
| Tank retention strap | KEEPER 85512 endless-loop ratchet tie-down, 1 inch × 13 feet | View endless-loop retaining strap | One strap; 400 lb working-load limit. Route around the cradle base/support bars according to the adapter instructions. Restrain the tank without crushing it; this is not a hoisting sling. |
| Electrical testing, optional | INNOVA 3320 auto-ranging digital multimeter | View digital multimeter | For DC-voltage, ground and continuity checks with correct terminal probes and circuit information. Never measure resistance on a powered circuit. Not a fuel-pressure gauge. |
| Initial code reading, optional | Autel AL319 OBD-II code reader | View OBD-II code reader | Reads supported stored/pending engine codes and freeze-frame data. It does not provide the Chrysler ASD Fuel System Test or establish TIPM bidirectional control. |
| Chrysler fuel-system actuation | Scan tool with verified ASD Fuel System Test capability | Match exact vehicle coverage or arrange professional testing | Required for the cited factory final pressure/leak test. Confirm the specific Chrysler year/engine and actuation function; the linked basic AL319 does not supply this function. |
| Fuel-pressure gauge and adapter | EFI pressure gauge with 6539-style 5/16-inch or 6631-style 3/8-inch fuel-line adapter | Match actual coupling or rent the specified setup | Gauge must cover the 59 ± 5 psi reference. Select a sealed EFI-compatible connection for the actual line; no universal retail kit is assumed to include the correct adapter. |
| New module sealing ring | Seal supplied with the featured A-Premium module | View module with sealing ring | A new seal is required whenever the module is removed. Inspect the supplied ring and match its shape to the tank groove; do not reuse the flattened old seal. |
Required support and diagnostic equipment: use a transmission jack or equivalent fuel-tank support with a broad, protected contact area and restraints suitable for the tank’s shape. Check that its minimum height fits the vehicle’s actual lift clearance. A bare floor-jack saddle is inadequate. A Chrysler-capable scan tool is needed for the factory ASD Fuel System Test, and pressure testing needs a gauge plus the correct 5/16- or 3/8-inch adapter. A basic code reader cannot be assumed to command the pump. These specialist tools may be rented or used by a repair shop for diagnosis and the final pressure/leak test.
Condition-dependent materials: replace a rusted/deformed lock ring, damaged quick-connector retainers, leaking filler hose or corroded mounting hardware with parts matched to the VIN and tank. Obtain those exact parts before reassembly; there is no universal seal, hose, fastener or clip kit for every vehicle in the table. Keep clean wipes and suitable fuel absorbent available.
DIY versus professional cost
These are planning estimates in US dollars, excluding tax, shipping, fuel disposal and unexpected damage. The comparison assumes one aftermarket module and a serviceable tank, connector and mounting straps. It is not a live product price or a shop quote.
| Cost category | DIY estimate | Professional planning allowance |
|---|---|---|
| Module | About $80–$160 | About $80–$250 for an aftermarket choice; an OE module may cost substantially more |
| Consumables / minor materials | About $15–$40 | About $20–$60 |
| Tools / rental | $0 if suitable equipment is owned; allow $200–$600+ if buying or renting | Normally included in the shop’s labor/overhead |
| Labor | Your time; estimated 3–5 hours | Illustrative 2–4 hours × $120–$200/hour = $240–$800 |
| Estimated total | About $95–$200 with tools owned; $295–$800+ with the tool allowance | About $340–$1,110 using the assumptions above |
Professional diagnosis before buying the pump can save the cost of replacing a good module. Ask whether the quote includes testing, the new seal, tank cleaning, damaged hardware and a leak check. Corrosion and a tank holding substantial fuel can add time.
Step-by-step repair overview: 2008 Town & Country 3.8L
1. Confirm the diagnosis and compare the replacement
Record the codes and test results. Match the module number, connector keying, outlet arrangement and sender configuration. Check that a new seal is present. Plan a clean place for the removed assembly and approved containment for residual fuel. If the tank is dirty, arrange cleaning before installing the new pump.
2. Relieve pressure and isolate power
If reaching the pump harness requires underbody access, safely raise and support the van before going underneath. With the key off, remove the filler cap and disconnect the pump-module harness using its lock and release tab. Start the engine and let it stall, then retry until it no longer runs; switch the ignition off. Cover the line connection with a wipe and contain residual fuel when releasing it. If the engine cannot run, do not assume pressure is gone: use the proper pressure-release equipment. Disconnect and secure battery negative before disassembly.
3. Raise the van and prepare the tank support
Chock the grounded wheels and lift/support at the vehicle’s specified points. Check working clearance with the support equipment in its lowered position. Position a suitable padded cradle beneath the tank and secure the tank to it. The support should carry the tank’s weight without lifting the van or crushing the tank. Keep fuel load manageable; do not force a siphon through the filler neck.
4. Release the tank connections
Fully identify the fuel, vapor and electrical connections before opening them. Release the filler-hose clamp and hose, pump/body harness, fuel quick connectors and EVAP connections. Disconnect the ESIM wiring and vapor hoses as required for tank lowering. Release secondary locks before pressing connector tabs; do not pull on wires or pry against brittle plastic ports. Protect open fittings from contamination.
5. Lower the tank under control
With the tank restrained and supported, remove its strap bolts and the vapor-canister bracket bolt. Lower slowly, pausing to free any remaining upper hoses or retainers. Never let a hidden connection carry the tank’s weight. Move the tank to a stable work position and keep the opening area clean. Use approved equipment and containers for fuel transfer.
6. Remove the module
Disconnect the module’s electrical and fuel connections. Clean around the flange before opening it; suitable cleaning and low-pressure filtered air keep debris away from the opening. Note the module’s orientation. Engage the correct retaining-ring tool fully and turn counterclockwise. Lift the assembly carefully, guiding the float through the opening without bending it and containing the fuel held inside.
7. Install the seal and module
Remove the old O-ring and inspect the groove, ring and tank flange. Install a new correctly seated seal. Lower the replacement without trapping the float and align its mounting tab with the arrow on the tank. Fit the ring and turn clockwise using the correct tool until it is fully seated and locked. Do not force a misaligned module or use sealant to compensate for a wrong seal.
8. Reinstall the tank and connections
Reconnect the module line and electrical plug, then raise the restrained tank into position. On this worked configuration, tighten the canister-bracket bolt and tank-strap bolts to 55 N·m (40.5 lb-ft). Reconnect ESIM, fuel, vapor and body-harness connections, engaging every safety retainer. Fully seat the filler hose, restore its clamp position and tighten securely. Check routing and pinch points before removing support.
9. Pressurize, check and road-test
Restore the fuel cap and electrical power after all connections are secured. Use the factory ASD Fuel System Test with compatible equipment to pressurize the system and inspect every opened joint. If there is wetness or fuel odor, switch off and correct the leak before starting. Check running pressure, starting behavior and gauge response. Clear only understood service-induced codes, then road-test and recheck for leaks or returning faults.
The key installation references are the 2008 3.8L module installation procedure and 2008 3.8L tank installation procedure. Use their vehicle-specific alignment and fastening details; do not transfer the numbers to a different tank or application without its service information.
Watch the fuel-pump replacement
Airtex-ASC Performance Pumps demonstrates replacement of the E7235M module family on 2008–2010 Town & Country/Grand Caravan applications. E7235M is an interchange reference for the featured module; the video does not show the exact A-Premium package. Match your fuel type, connectors and module orientation. Follow the factory lock-ring-tool method and the worked vehicle’s specifications above.
Common mistakes to avoid
- Ordering by the broad year range while overlooking the gasoline/flex-fuel distinction or the restricted 3.3L application.
- Replacing the module for P0627 without checking the upstream control circuit, or replacing it for a gauge fault without testing the sender wiring.
- Using an unsuitable jack saddle or trying to lower a tank still attached to a hose, wire or canister bracket.
- Dropping dirt into the tank, bending the float arm, reusing the old seal or leaving the retaining ring partly engaged.
- Forcing a line-release tool into a connector with a different locking design.
- Finishing the job without pressurizing and inspecting the opened connections before starting.
Frequently asked questions
Can I reach the pump through the interior floor?
The service procedure for this worked configuration removes the fuel tank. Do not cut the floor to create an opening; that adds a fire hazard and can damage the vehicle.
Will the new pump fix P0627?
Only if testing establishes a fault that the replacement actually corrects. P0627 concerns pump control, so wiring or the TIPM/PCM control path may require separate repair.
Does this fit every 2008–2010 minivan?
No. Follow the engine and fuel-type rows above. In particular, the 3.3L listing covers only the 2008 gasoline Town & Country, and it does not establish fitment for a 3.3L Grand Caravan.
Should I change the seal even if it looks good?
Yes. The worked service procedure requires a new module O-ring. The featured listing includes a sealing ring, which should be inspected and matched before use.
Can I use a basic code reader for the whole job?
It can help record supported engine codes, but it is not a substitute for pressure-testing adapters, loaded electrical tests or a Chrysler-capable tool for the ASD Fuel System Test.
Sources and further reading
- A-Premium APFP0285 product specifications and application catalog
- Featured product listing: ASIN B07GZN8F8J
- Chrysler service information: 2008 Town & Country 3.8L tank installation (Operation CHARM reproduction)
- Chrysler service information: 2008 Town & Country 3.8L module installation (Operation CHARM reproduction)
- Chrysler service information: 2008 Town & Country 3.8L fuel-pressure testing (Operation CHARM reproduction)
- 2008 RT-platform fuel-pressure release procedure (Workshop Manuals reproduction)
- Chrysler P0627 diagnostic procedure, 2009 Grand Caravan 3.8L (Operation CHARM reproduction)
- Delphi: loaded electrical supply and voltage-drop testing
- Delphi: testing and replacing a fuel sending unit
- OTC 6599 manufacturer application and drive requirements
- 911 Motorsports four-point jack-adapter setup and restraint instructions
- Airtex-ASC Performance Pumps: E7235M installation video
- Browse more HowToMechanic repair guides