Durango, 2001-2005

Fuel Pump

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Removal & Installation



  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Fuel pump module harness connector
     
    Fuel line
     
    Fuel tank
     
    Fuel pump module locknut
     
    Fuel pump module

    Click image to see an enlarged view

    Fig. Fuel pump module locknut removal-2001-03 models

    Fuel pump module locknut removal-2001-03 models
     

  6.  

To install:

  1. Install or connect the following:

    Fuel pump module
     
    Fuel pump module locknut
     
    Fuel tank
     
    Fuel line
     
    Fuel pump module harness connector
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Drain and remove fuel tank.
  4.  
  5. Note rotational position of module before attempting removal. An indexing arrow is located on top of module for this purpose.
  6.  
  7. Position Special Tool 9340 into notches on outside edge of lockring.
  8.  
  9. Install 1 / 2 inch drive breaker bar to tool 9340.
  10.  
  11. Rotate breaker bar counter-clockwise to remove lockring.
  12.  
  13. Remove lockring. The module will spring up slightly when lockring is removed.
  14.  
  15. Remove module from fuel tank. Be careful not to bend float arm while removing.

    Click image to see an enlarged view

    Fig. Module lockring removal. (1) breaker bar, (2) fuel return line, (3) lockring tool, (4) module, (5) lockring-2004-05 models

    Module lockring removal. (1) breaker bar, (2) fuel return line, (3) lockring tool, (4) module, (5) lockring-2004-05 models
  16.  

To install:


CAUTION
Whenever the fuel pump module is serviced, the rubber seal (gasket) must be replaced.

  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 1 / 2 inch drive breaker (1) into Special Tool 9340.
  10.  
  11. Tighten lockring (clockwise) until all seven notches have engaged.
  12.  
  13. Install fuel tank.
  14.  

 
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