Chrysler Neon 1995-1999 Repair Guide

Fuel Pump

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The fuel pump is integral with the pump module, which also contains the fuel reservoir, level sensor, inlet strainer and fuel pressure regulator. The inlet strainer, fuel pressure regulator and level sensor are the only serviceable items. If the fuel pump requires service, replace the entire fuel pump module.

REMOVAL & INSTALLATION



1995 Vehicles

See Figures 1 and 2

  1. Disconnect the negative battery cable.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Drain the fuel tank, as outlined under the fuel tank removal and installation procedure.
  8.  


WARNING
The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir will spill out when the module is removed.

  1. Disconnect the fuel lines from the fuel pump module by depressing the quick-connect retainers with your thumb and fore-finger.
  2.  
  3. Using a hammer and brass drift punch, carefully tap the lock ring counterclockwise to release the pump.
  4.  



Click image to see an enlarged view

Fig. Fig. 1: Carefully tap the lock ring counterclockwise to release the fuel pump

  1. Remove the fuel pump and O-ring seal from the tank. Discard the old seal.
  2.  



Click image to see an enlarged view

Fig. Fig. 2: The fuel module assembly contains the pump, pressure regulator, reservoir, inlet strainer and level sensor

To install:
  1. Wipe the area of the tank clean, then place a new O-ring seal in proper position on the pump.
  2.  
  3. Position the fuel pump in the tank with the locking ring.
  4.  
  5. Using a hammer and brass drift, drive the ring around in a clockwise direction to lock the pump in place.
  6.  


CAUTION
Do not overtighten the pump lock ring, as this may cause a fuel leak.

  1. Carefully lower the vehicle.
  2.  
  3. Fill the fuel tank, the check for leaks.
  4.  
  5. Connect the negative battery cable.
  6.  

1996-99 Vehicles

See Figure 3

  1. Disconnect the negative battery cable.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Drain the fuel tank, as outlined under the fuel tank removal and installation procedure.
  8.  


WARNING
The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir will spill out when the module is removed.

  1. Disconnect the fuel lines from the fuel pump module by depressing the quick-connect retainers with your thumb and fore-finger.
  2.  
  3. Slide the fuel pump module electrical lock to unlock it.
  4.  
  5. Detach the electrical connection from the fuel pump module, by pushing down on the connector retainer and pulling the connector off of the module.
  6.  
  7. Use a transmission jack to safely support the fuel tank, then remove the bolts from the fuel tank straps.
  8.  
  9. Carefully lower the tank slightly for access to the module.
  10.  
  11. Use a ratchet and spanner wrench to remove the fuel pump module locknut.
  12.  



Click image to see an enlarged view

Fig. Fig. 3: To loosen the fuel pump module locknut, use a ratchet and spanner wrench

  1. Remove the fuel pump and O-ring seal from the tank. Discard the old seal.
  2.  

To install:
  1. Wipe the area of the tank clean, then place a new O-ring seal in position in the tank opening.
  2.  
  3. Position the fuel pump in the tank. Make sure the alignment tab on the underside of the fuel pump module flange sits in the notch on the fuel tank.
  4.  
  5. Position the locknut over the fuel pump module.
  6.  
  7. Using the ratchet and spanner wrench, tighten the locknut to 21 ft. lbs. (33 Nm).
  8.  
  9. Carefully lower the vehicle, then check for leaks.
  10.  
  11. Connect the negative battery cable.
  12.  

TESTING



See Figure 4

The fuel pump operates at about 29 psi (118 kPa). The fuel system pressure is checked at the test port on the fuel rail.

  1. Remove the cap from the fuel pressure test port on the fuel rail.
  2.  
  3. Connect a suitable fuel pressure gauge to the test port.
  4.  



Click image to see an enlarged view

Fig. Fig. 4: Attach a suitable fuel pressure gauge to the test port

  1. Unplug the fuel pump connector. Apply 12 volts directly to the fuel pump connector.
  2.  
  3. Note the gauge reading and compare with the following:

    If the gauge reading equals approximately 29 psi (118 kPa), no further testing is required. If the pressure is not correct, record the reading.
     
    If the fuel pressure is below specifications, check for a restricted fuel pump inlet strainer. If its restricted, replace the inlet strainer. If not restricted, check for an incorrectly operating fuel filter/regulator or fuel pump and replace as necessary.
     
    If the fuel pressure is above specifications (32 psi or higher), check for a kinked or restricted fuel supply line. If the line is not kinked or restricted, check for a restriction in the chassis fuel supply line or for kinked or plugged fuel supply line. If none of the lines are restricted, replace the filter/regulator.
     

  4.  
  5. After the test is complete, remove the test equipment and reconnect the fuel pump harness.
  6.  

 
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