How do you replace a fuel pump on a 1996 Chrysler Concorde?

Answer 1

I just replaced my fuel pump on a 1996 Chrysler Concorde. I'm no mechanic but it wasn't that difficult.

If you know the fuel pump is the issue and it will definitely need to be replaced, I suggest having the part available because there are instructions for safety in the packaging of the part that I was not aware of when I removed my original Fuel Pump Assembly (FPA).

Here's how I did it:

Clean out the trunk. I did all of my work through the trunk. Did not have to remove the seats from back of car. Pull back the carpeting in trunk but you should not have to remove it.

In the back of the trunk remove 4 nuts. Remove plate. I suggest keeping removed items away from your working space because you will not want to drop anything either down the exposed opening or in the gas tank after the FPA is removed.

Next, disconnect three hoses/tubes from top of the FPA. NOTE: One of these hoses (the smallest) attaches to a cylindrical device called a rollover valve. Take note of the orientation of this device, first because you will have to remove and reuse this part (it is not included in the replacement FPA) and also because you could become confused on which way it needs to go back in. Keep in mind that as you pull these tubes off that a small amount of gasoline is likely to spill.

Also disconnect the electrical fitting by just pulling it out.

The two larger tubes mentioned above have a snap-in assembly in the inner diameter of the bell shaped end of the tubes that you will also need to reuse. I used a small screw driver to delicately defeat the snaps so that I could pull the tubes off. They are each a different size so you're not likely to confuse them.

Now you are ready to remove the FPA by loosening the S/S band that goes around the top perimeter of the FPA. This was a challenging task but to get it out I managed to do it with a short screw driver as this is a tight space. When I put the band back on during the reinstallation of the FPA at the end of my project I was wise enough to have already purchased a small ratchet set which was almost a necessity as I look back. I got it at a local hardware store for $9 and it was worth buying for just this one project.

When the band is loosened the pump is ready to come out. A few notes: The FPA pump has attached to it what I assume is a float device for fuel level indication. This may impede to a small extent the removal of the FPA but with a little tilting and lifting it will come out easily. Again keep in mind this unit will have a decent amount of gas in it, some of which will likely spill.

Remember that the rollover valve is in your removed FPA and will have to be transfered to the replacement FPA. I could not get mine off of the old unit by pulling. It fits down through a rubber grommet and should simply pull straight out of the opening in theory, but mine would not so I got a hack saw and carefully cut it out of the removed FPA.

I was able to push the reused rollover valve into the new FPA but I did use a soapy lubricant to get it to go easily. Obviously, wipe off any lubricant that you use for this before placing the FPA unit back into the fuel tank.