Dakota 2006-2007

Fuel Pump

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Release fuel system pressure.
  4.  
  5. Raise vehicle.
  6.  
  7. Remove left rear tire/wheel.
  8.  
  9. Remove plastic fender liner in front of left-rear tire/wheel.
  10.  
  11. Thoroughly clean area around fuel fill fitting and rubber fuel fill hose at fuel tank.
  12.  
  13. Loosen clamp and disconnect rubber fuel fill hose at fuel tank fitting. Using an approved gas holding tank, drain fuel tank through this fitting.
  14.  
  15. Disconnect vent line from tank.
  16.  
  17. If equipped, remove fuel tank skid plate.
  18.  
  19. Disconnect NVLD, ORVR and EVAP lines at front of tank.
  20.  
  21. Disconnect electrical connector at NVLD pump.
  22.  
  23. Support tank with a hydraulic jack.
  24.  
  25. Remove two fuel tank strap nuts and remove both tank support straps.
  26.  
  27. Carefully lower tank a few inches and disconnect fuel pump module electrical connector at top of tank. To disconnect electrical connector: Push upward on red colored tab to unlock. Push on black colored tab while removing connector.
  28.  
  29. Disconnect fuel line at fuel pump module fitting by pressing on tabs at side of quick-connect fitting.
  30.  
  31. Continue to lower tank for removal.
  32.  
  33. Note rotational position of module before attempting removal. An indexing arrow is located on top of module for this purpose.
  34.  
  35. Position Special Tool 9340 into notches on outside edge of lockring.
  36.  
  37. Install 1 / 2 inch drive breaker bar to tool 9340.
  38.  
  39. Rotate breaker bar counter-clockwise to remove lockring.
  40.  
  41. Remove lockring. The module will spring up slightly when lockring is removed.
  42.  
  43. Remove module from fuel tank. Be careful not to bend float arm while removing.

    Click image to see an enlarged view

    Fig. Lockring removal

  44.  

To install:

  1. Using a new seal (gasket), position fuel pump module into opening in fuel tank.
  2.  
  3. Position lockring over top of fuel pump module.
  4.  
  5. Rotate module until embossed alignment arrow points to center alignment mark. This step must be performed to prevent float from contacting side of fuel tank. Also be sure fuel fitting on top of pump module is pointed to driver-s side of vehicle.
  6.  
  7. Install Special Tool 9340 to lockring.
  8.  
  9. Install breaker into Special Tool 9340.
  10.  
  11. Tighten lockring (clockwise) until all seven notches have engaged.
  12.  
  13. Install fuel tank.
  14.  
  15. Position fuel tank to hydraulic jack.
  16.  
  17. Raise tank until positioned near body.
  18.  
  19. Connect fuel pump module electrical connector at top of tank.
  20.  
  21. Connect NVLD pump electrical connector to NVLD pump.
  22.  
  23. Connect fuel line quick-connect fitting to pump module.
  24.  
  25. Continue raising tank until positioned snug to body.
  26.  
  27. Install and position both tank support straps. Install two fuel tank strap nuts and tighten to 30 ft. lbs. (41 Nm).
  28.  
  29. Connect EVAP, ORVR and NVLD lines at front of tank.
  30.  
  31. Connect vent line.
  32.  
  33. Connect rubber fill hose to fuel tank fitting and tighten hose clamps.
  34.  
  35. The vapor/vacuum lines and hoses must be firmly connected. Also check the vapor/vacuum lines at the NVLD pump, NVLD filter and EVAP canister purge solenoid for damage or leaks. If a leak is present, a Diagnostic Trouble Code (DTC) may be set.
  36.  
  37. If equipped, install fuel tank skid plate.
  38.  
  39. Install plastic liner in front of left-rear tire/wheel.
  40.  
  41. Install left rear tire/wheel.
  42.  
  43. Lower vehicle.
  44.  
  45. Fill fuel tank with fuel.
  46.  
  47. Start engine and check for fuel leaks near top of module.
  48.  

 
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