Avenger 2008

Removal & Installation

Print

4wd Models



Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009


WARNING
The fuel system is under constant pressure even with engine off. Until the fuel pressure has been properly relieved from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Wear protective clothing and eye protection. Make sure the area in which the vehicle is being serviced is in a well ventilated area.

  1. Remove fuel filler cap.
  2.  
  3. Remove the rear seat cushion.
  4.  
  5. Remove fuel pump module cover (1).
    WARNING
    Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. This may result in personal injury or death.



    Click image to see an enlarged view

    Fig. Remove fuel pump module cover (1)

  6.  
  7. Release the fuel system pressure.
  8.  
  9. Disconnect the quick connect fitting (3) of the fuel supply line from the fuel pump module.

    Click image to see an enlarged view

    Fig. Disconnect the quick connect fitting (3) of the fuel supply line from the fuel pump module

  10.  
  11. Remove the fuel pump module lock ring using SAE Fuel Pump Lock Ring Wrench 9340.

    Click image to see an enlarged view

    Fig. Remove fuel pump module lock using special tool 9340

  12.  
  13. Note the fuel pump location on the top of the fuel tank.
    NOTE
    The pump has to be properly located to the tank for the fuel gauge to work properly.

  14.  
  15. Push down on fuel pump module and remove lock ring.

    Click image to see an enlarged view

    Fig. Push down on fuel pump module and remove lock ring

  16.  
  17. Pull module up out of fuel tank, make sure that you do not spill fuel inside of vehicle.
  18.  
  19. Drain fuel from fuel pump module into an approved fuel storage container. Do not spill fuel in interior of vehicle.
  20.  
  21. Transfer fuel from fuel tank into an approved fuel storage container.
  22.  
  23. Raise and support the vehicle.
  24.  
  25. Remove close-out panels (1) and (2).

    Click image to see an enlarged view

    Fig. Remove close-out panels (1) and (2)

  26.  
  27. Remove the exhaust system.
  28.  
  29. On vehicles equipped with a convertible top, remove the two front bolts (1) from the cross-braces (2).

    Click image to see an enlarged view

    Fig. Remove the two front bolts (1) from the cross-braces (2)

  30.  
  31. Disconnect the quick connect fitting (1) from the fuel tank vapor line (2).

    Click image to see an enlarged view

    Fig. Disconnect the quick connect fitting (1) from the fuel tank vapor line (2)

  32.  
  33. Disconnect the quick connect fitting (2) and remove the fuel tube vent line (1).

    Click image to see an enlarged view

    Fig. Disconnect the quick connect fitting (2) and remove the fuel tube vent line (1)

  34.  
  35. Loosen the hose clamp (3) and remove the fuel filler tube (4) from the fuel tank.
  36.  
  37. Disconnect the quick connect fitting (1) from the fuel supply line.
    WARNING
    Support fuel tank with a transmission jack or equivalent. Use straps to secure the fuel tank to the jack. Failure to properly support and secure the fuel tank during removal may cause fuel to spill or fuel tank to fall from jack assembly.



    Click image to see an enlarged view

    Fig. Disconnect the quick connect fitting (1) from the fuel supply line

  38.  
  39. Use a transmission jack to support fuel tank (3), remove fuel tank strap bolts (2) and straps (1).
  40.  
  41. Lower fuel tank (3) from vehicle.
  42.  
  43. If fuel tank is to be replaced, remove fuel line (1) from fuel tank.

    Click image to see an enlarged view

    Fig. Remove fuel line (1) from fuel tank

  44.  
  45. If fuel tank is to be replaced, remove heat shield (1) from fuel tank.

    Click image to see an enlarged view

    Fig. Remove heat shield (1) from fuel tank

  46.  

To install:

  1. If fuel tank was replaced, install heat shield to fuel tank.
  2.  
  3. Install o-ring seal and fuel pump module in marked location.
  4.  
  5. Install fuel pump module lock ring, push module down and start lock ring.
  6.  
  7. Finish installation of the fuel pump module lock ring using SAE Fuel Pump Lock Ring Wrench 9340.
  8.  
  9. Install fuel supply line to fuel tank and connect to fuel pump module.
    WARNING
    Support fuel tank with a transmission jack or equivalent. Use straps to secure the fuel tank to the jack. Failure to properly support and secure the fuel tank during removal may cause fuel to spill or fuel tank to fall from jack assembly.

  10.  
  11. Position fuel tank onto a transmission jack or equivalent and raise the fuel tank into vehicle position.
  12.  
  13. Install the straps and fuel tank strap bolts. Tighten to 35 ft. lbs. (48 Nm).
  14.  
  15. Install fuel filler tube to the fuel tank.
  16.  
  17. Install the fuel tube vent line to the quick connect fitting.
  18.  
  19. Connect the tank vapor line quick connect fitting.
  20.  
  21. Connect the quick connect fitting to the fuel supply line.
  22.  
  23. On vehicles equipped with a convertible top, install the two front bolts to the cross-braces. Tighten bolts to 35 ft. lbs. (48 Nm).
  24.  
  25. Install the exhaust system.
  26.  
  27. Install close-out panels.
  28.  
  29. Lower vehicle.
  30.  
  31. Connect fuel pump/module electrical connector.
  32.  
  33. Install fuel pump module cover.
  34.  
  35. Install rear seat cushion.
  36.  
  37. Fill fuel tank and install fuel filler cap.
  38.  
  39. Connect negative battery cable.
    NOTE
    After servicing the fuel system, one or more Diagnostic Trouble Codes (DTC's) may have been stored in Powertrain Control Module (PCM) memory due to disconnecting fuel pump module circuit. A diagnostic scan tool must be used to erase a DTC.

  40.  
  41. Use the scan tool to pressurize the fuel system. Check for leaks.
  42.  

All Wheel Drive



Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009


WARNING
The fuel system is under constant pressure even with engine off. Until the fuel pressure has been properly relieved from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Wear protective clothing and eye protection. Make sure the area in which the vehicle is being serviced is in a well ventilated area.

  1. Remove fuel filler cap.
  2.  
  3. Remove the rear seat cushion.
  4.  
  5. Remove fuel pump module cover (1).
    WARNING
    Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. This may result in personal injury or death.



    Click image to see an enlarged view

    Fig. Remove fuel pump module cover (1)

  6.  
  7. Release the fuel system pressure.
  8.  
  9. Remove the fuel pump module lock using special tool 9340.
    NOTE
    The pump has to be properly located to the tank for the fuel gauge to work properly.



    Click image to see an enlarged view

    Fig. Remove fuel pump module lock using special tool 9340

  10.  
  11. Mark the fuel pump location on the top of the fuel tank.
  12.  
  13. Push down on fuel pump module and remove lock ring.

    Click image to see an enlarged view

    Fig. Push down on fuel pump module and remove lock ring

  14.  
  15. Pull module up out of fuel tank, make sure no fuel spills inside of the vehicle.
  16.  
  17. Drain fuel from fuel pump module into an approved fuel storage container. Do not spill fuel in interior of vehicle.
  18.  
  19. Raise and support the vehicle.
  20.  
  21. Disconnect the fuel pump module quick connect fitting (1) from the fuel delivery line (2).

    Click image to see an enlarged view

    Fig. Disconnect the fuel pump module quick connect fitting (1) from the fuel delivery line (2)

  22.  
  23. Disconnect fuel tank vapor line (1).

    Click image to see an enlarged view

    Fig. Disconnect fuel tank vapor line (1)

  24.  
  25. Disconnect the quick connect fitting (2) and remove the fuel tube vent line (1).

    Click image to see an enlarged view

    Fig. Disconnect the quick connect fitting (2) and remove the fuel tube vent line (1)

  26.  
  27. Loosen the hose clamp (3) and remove the fuel filler tube (4) from the fuel tank.
  28.  
  29. Remove the canister hose (2) to tank connection (1).

    Click image to see an enlarged view

    Fig. Remove the canister hose (2) to tank connection (1)

  30.  
  31. Remove electronically controlled clutch (1).
    WARNING
    Support fuel tank with a transmission jack or equivalent. Use straps to secure the fuel tank to the jack. Failure to properly support and secure the fuel tank during removal may cause fuel to spill or fuel tank to fall from jack assembly.



    Click image to see an enlarged view

    Fig. Remove electronically controlled clutch (1)

  32.  
  33. Use a transmission jack to support fuel tank (1), remove fuel tank strap bolts (2) and straps (3).

    Click image to see an enlarged view

    Fig. Remove fuel tank strap bolts (2) and straps (3)

  34.  
  35. Disconnect the electrical connector from the fuel level sensor.
  36.  
  37. Lower fuel tank (3) from vehicle.
  38.  
  39. Remove fuel pump line from fuel tank.
  40.  
  41. Transfer fuel into an approved fuel storage container.
  42.  
  43. Remove nuts (1) and fuel tank shield (3) from fuel tank (2).

    Click image to see an enlarged view

    Fig. Remove nuts (1) and fuel tank shield (3) from fuel tank (2)

  44.  

To install:

  1. Install fuel tank shield nuts to fuel tank.
    WARNING
    Support fuel tank with a transmission jack or equivalent. Use straps to secure the fuel tank to the jack. Failure to properly support and secure the fuel tank during removal may cause fuel to spill or fuel tank to fall from jack assembly.

  2.  
  3. Install fuel line to fuel tank.
  4.  
  5. Position fuel tank onto a transmission jack or equivalent and raise the fuel tank into vehicle position.
  6.  
  7. Connect electrical connector to fuel level sensor.
  8.  
  9. Install fuel tank straps and bolts. Tighten to 35 ft. lbs. (48 Nm).
  10.  
  11. Install electronically controlled clutch.
  12.  
  13. Install canister hose to tank connection.
  14.  
  15. Install fuel tube vent line to the quick connect fitting.
  16.  
  17. Install fuel filler tube to fuel tank.
  18.  
  19. Connect fuel tank vapor line.
  20.  
  21. Connect fuel pump module quick connect fitting to fuel delivery line.
  22.  
  23. Wipe seal area of tank clean and install a new O-ring seal to fuel tank.
  24.  
  25. Connect fuel line between fuel pump module and fuel level unit.
  26.  
  27. Install fuel pump module to fuel tank.
  28.  
  29. Position fuel pump module into fuel tank, line up module with mark made during removal procedure. Install fuel pump module lock using special tool 9340. Tighten until the lockring and fuel pump module is fully seated.
  30.  
  31. Connect fuel line to fuel pump module.
  32.  
  33. Connect the electrical connector.
  34.  
  35. Connect the battery cable.
  36.  
  37. Fill fuel tank.
  38.  
  39. Use the scan tool to pressurize the fuel system.
  40.  
  41. Check for leaks.
  42.  

 
label.common.footer.alt.autozoneLogo