300M, Concorde, Intrepid, LHS, 1998-2004

Fuel Pump

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Removal & Installation



The in-tank fuel pump module contains the fuel pump and pressure regulator which adjusts fuel system pressure. Fuel pump voltage is supplied through the fuel pump relay.

The fuel pump is serviced as part of the fuel pump module. The fuel pump module is installed in the top of the fuel tank and contains the electric fuel pump, fuel pump reservoir, inlet strainer fuel gauge sending unit, fuel supply and return line connections and the pressure regulator. The inlet strainer, fuel pressure regulator and level sensor are the only serviceable items. If the fuel pump requires service, replace the fuel pump module.

  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 tank
     

  6.  
  7. Clean the top of the tank to remove any loose dirt.

    Fuel lines from the fuel pump module by squeezing the quick-connect fitting with thumb and forefinger

    Click image to see an enlarged view

    Fig. Using special tool 6856, remove the fuel pump module locknut

     
    Fuel pump module electrical connector from the top of the fuel pump module
     

  8.  
  9. Using special tool 6856, remove the fuel pump locknut by turning it counterclockwise.
    CAUTION
    The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed.

  10.  
  11. Remove the fuel pump and O-ring from the tank and discard the O-ring.
  12.  

To install:

  1. Thoroughly clean all parts. Wipe the seal area of the tank clean. Place a new O-ring on the ledge between the tank threads and the pump module opening.
  2.  
  3. Position the fuel pump module in the tank. Be sure the alignment tab on the underside of the pump module flange sits in the corresponding notch in the fuel tank.
  4.  
  5. While holding the fuel pump module in place install the locking ring and torque to 40 inch lbs. (5 Nm) using special tool 6856 or a spanner-type tool.
  6.  
  7. Install or connect the following:

    Fuel tank
     
    Fuel pump module electrical connector
     
    Negative battery cable
     

  8.  
  9. Fill the fuel tank with fuel. Install the fuel filler cap. Turn the ignition switch to the ON position to pressurize the system. Check the fuel system for leaks.
  10.  

 
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