How do you replace the fuel pump on a dodge durango?

Answer 1

Replace 1999 Durango Fuel Pump - GeneralThe fuel pump and associated filter are in the gas tank. You must remove the gas tank from the vehicle as it is inserted into the gas tank and attached to the tank from the top. Some things to know (these steps may not be complete, but they will give you an idea of the effort required):

1) it helps if the gas tank is empty or near empty before you start (Gas is heavy - roughly 8 lbs per gallon, the fumes travel far and fast and can ignite with the smallest spark). Siphon all you can get out of the tank before begining.

2) remove gas cap (if you have not already done this as it will release any built up pressure in your gas tank).

3) release pressure from fuel lines (fairly high pressure)

a)pull fuel pump relay from underhood fuse box (ignition switch off)

b)start car and let it idle until it runs out of gas and quits

c)replace fuel pump relay (ignition switch off)

4) remove negative battery cable (sparks and gas are not happy together)

5 you may have to jack vehicle up to get access to gas tank underneath (use proper jack stands, never never trust a jack)

6) disconnect filler hose & vent hose from gas tank (usually simple hose clamps) they should be at the back of the tank

7) place jack or blocks under tank as you are about to remove the straps that hold gas tank in place - but you must initially let tank down only enough to disconnect fuel line, vent line and electrical connector. There will not be enough slack in these lines and wires to drop the tank to the ground and then disconnect them so be prepared to completely control the weight of the tank. This is another reason to empty the tank.

8) lower gas tank to the ground and move it away from the vehicle

9) before removing metal retaining ring from fuel pump, notice the orientation of the gas pump. The package is round. If the new pump is not install in exactly the same position your fuel guage float may not work properly. I would suggest making a mark on the old fuel pump and on the tank that line up prior to removing original pump. Then if your memory fails, you can look at the old pump and the tank and see exactly where it should go.

10) remove the metal retaining ring by turning it to release the plastic tabs that are all around the fuel pump. There should also be a locking tab that may have to be pulled back or pryed away from the metal ring before it can be turned. You may have to take a wooden dowel or brass bar and a hammer and gently tap the ring to move it while someone else holds the locking tab back. Never use anything metal to tap on the metal ring as it can create sparks.

11) after ring is removed, gently remove the fuel pump. You will likely have to tilt the unit slightly to get it out of the tank as the fuel float will be attached. DO NOT DAMAGE THE FLOAT as I do not think the new pump will come with one and it will have to be reused. DO NOT DROP the Rubber Gasket in the tank - seems like common sense until you drop one in and spend the next 15 minutes fishing it out.

12) install the new pump by doing everything above in reverse.