Avenger, Sebring Coupe, Stratus Coupe, 1999-2006

Removal & Installation

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A replaceable fuel filter is located in the engine compartment, on the bulkhead, next to the brake booster.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
  6.  
  7. Remove the air intake hose for access.
  8.  
  9. Hold the fuel filter housing securely with a wrench. Cover the hoses with shop towels and remove the banjo bolt. Discard the gaskets.
  10.  
  11. Separate the flare nut connection at the bottom of the filter.
  12.  
  13. Remove the mounting bolts and the fuel filter from the vehicle.
    CAUTION
    Do not use conventional fuel filters, hoses or clamps when servicing fuel injection systems. They are not compatible with the high pressures used in fuel injection systems. Use only hoses and clamps specifically designed for fuel injection.



    Click image to see an enlarged view

    Fig. Exploded view of the fuel line-to-filter connection

  14.  

To install:

  1. Tighten the flare nut fitting by hand before mounting the filter on the bracket.
  2.  
  3. Install the filter on its bracket only finger-tight. Movement of the filter will ease attachment of the fuel lines.
  4.  
  5. Using new gaskets, connect the high pressure hose and banjo bolt. While holding the fuel filter housing, torque the banjo bolt to 22 ft. lbs. (29 Nm). Torque the flare nut to 27 ft. lbs. (36 Nm).
  6.  
  7. Tighten the filter mounting bolts fully.
  8.  
  9. Install the intake air hose, if removed.
  10.  
  11. Connect the negative battery cable, turn the key to the ON position to pressurize the fuel system and check for leaks.
  12.  
  13. Start the vehicle, check for leaks and repair if necessary.
  14.  

The 1999-00 fuel delivery system contains a replaceable inline filter. The fuel filter mounts to the frame above the rear of the fuel tank. The fuel tank assembly must be loosened and lowered slightly to access the filter. The inlet and outlet tubes are permanently attached to the filter. Please note that the fuel system pressure must be relieved before servicing fuel system components. In addition, quick-disconnect fittings are used on fuel line connections. When the tubes are fully connected, the locking ears and the fuel tube shoulder are visible in the windows of the connector.

Click image to see an enlarged view

Fig. Be sure the shoulder and locking tabs are visible through the window of the connector when attached

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure using the recommended procedure.
    NOTE
    The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.

  4.  
  5. Disconnect the negative battery cable from the left shock tower.
  6.  
  7. From inside the trunk, disconnect the fuel pump module wiring jumper from the main body harness. The 4-pin connector is located under the trunk mat on the left side of the trunk near the base of the shock tower. Locate the body grommet for the jumper near the base of the rear seat. Push the grommet out and feed the jumper completely through the hole in the body.
  8.  
  9. Remove the fuel cap slowly to release tank pressure.
  10.  
  11. Raise and safely support the vehicle.
  12.  
  13. Locate the drain plug on the bottom left of the fuel tank. Place an approved fuel container with a capacity of at least 16 gallons, under the drain plug. Remove the plug and drain the fuel tank. When finished draining, install the plug since there will be 1-2 gallons of fuel remaining. Tighten the drain plug to 32 inch lbs. (3.6 Nm).
  14.  
  15. Remove or disconnect the following:
    NOTE
    Allow the tank to lower until the fuel tank neck touches the rear suspension crossmember.


    CAUTION
    Wrap shop towels around the fuel hoses to catch any gasoline spillage.



    Driver's side fuel tank strap
     
    Passenger's side fuel tank strap loosen it
     



    Fuel line quick-disconnect fittings from the fuel pump module. Squeeze fuel filter hose connector releasing tabs and detach the fuel lines
     
    Fuel filter

    Click image to see an enlarged view

    Fig. Fuel filter mounting location-1999-00 models

     

  16.  

To install:


NOTE
The fuel supply (to filter) tube and the return tube (to fuel pump module) are permanently attached to the fuel filter. The ends of the fuel supply and return tubes have different size quick-disconnect fittings. The large quick-disconnect fitting attaches to the large nipple (supply side) on the fuel pump module. The smaller quick-disconnect fitting attaches the small nipple (return side) on the fuel pump module.

  1. Lubricate the fuel filter nipples with engine oil.
  2.  
  3. Install or connect the following:
    NOTE
    Be sure the fuel pump module electrical harness grommet is installed in the body as the tank is raised into position.



    Fuel tubes
     
    Fuel tank raise it into position
     
    Fuel tank straps and torque the bolts to 17 ft. lbs. (23 Nm)
     



    Fuel pump module connector
     
    Negative battery cable
     

  4.  
  5. Refill the fuel tank.
  6.  

The 2001-05 fuel delivery system integrates the fuel filter with the in-tank fuel pump

The fuel delivery system integrates the fuel filter with the in-tank fuel pump.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    The negative battery cable
     
    The fuel pump module
     
    The locking tabs on the fuel pump
     
    The strainer and O-ring
     
    The inlet filter from the assembly
     

  6.  

To install:

  1. Install or connect the following:

    The inlet filter
     
    The new O-ring and strainer
     
    The locking tabs on the fuel pump module
     
    The fuel pump module
     
    The negative battery cable
     

  2.  
  3. Start the vehicle, check for leaks and repair if necessary.
  4.  

Inlet Filter



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Fuel pump module
     
    Locking tabs on the fuel pump
     
    Strainer and O-ring
     
    Inlet filter from the assembly
     

  6.  

To install:

  1. Install or connect the following:

    Inlet filter
     
    New O-ring and strainer
     
    Locking tabs on the fuel pump module
     
    Fuel pump Module
     
    Negative battery cable
     

  2.  
  3. Start the vehicle, check for leaks and repair if necessary.
  4.  

 
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