Question about 1997 Dodge Intrepid

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How to rplace the fuel pump+ - 1997 Dodge Intrepid

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ZJ Limited

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Check this procedure to REMOVAL & INSTALLATION
(see Figures 1, 2 and 3 / click over pics for zoom)

how to rplace the fuel - zjlimited_258.jpg

Fig. 1: Remove the nuts retaining the access cover in the trunk


Fig. 2: Once the cover is removed, access to the pump is obtained

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Fig. 3: Note the alignment marks must be met to install the pump correctly
An electric fuel pump is used with fuel injection systems in order to provide higher and more uniform fuel pressures. It is located in the tank. To perform the testing or servicing, you will need a DRB III or equivalent scan tool.

  1. Release the fuel system pressure.
  2. Disconnect the negative battery cable.
  3. Open the trunk lid, then remove the trunk liner.
  4. Remove the access panel fasteners.
  5. Remove the access panel and gasket. Inspect the gasket for damage. If necessary, replace the gasket.
  6. Disconnect the electrical wiring from the top of the pump module.
  7. Disconnect the fuel supply and return tubes from the fuel pump module.
  8. Disconnect the hose from the pressure relief/rollover valve.
  9. A band clamp fastens the pump module to the tank. The module rises up from the tank after loosening the clamp.
  10. Loosen the band clamp until the pump module rises up from the tank.
WARNING The pump reservoir may contain fuel. Do not spill fuel while removing the module.
  1. To absorb any possible spillage, place a shop towel around the access opening. Without removing the modular, tip it backwards to allow fuel in the reservoir to run down the side and back into the tank.
  2. The float arm of the sensor catches on the inside of the tank while removing the module. Tilt the module to the one side when removing it from the tank.
  3. Remove the pump module and gasket from the tank.
  4. Drain the remainder of fuel from the reservoir before servicing the pump module.
To install:

The fuel pump module and tank have alignment marks. The tank has two molded lines at the ten o'clock position. The fuel pump has a triangular alignment mark. Align the marks to correctly position the pump.
  1. With a new gasket, insert the pump straight into the tank to set the float on the bottom. Align the marks on the pump and tank.
  2. Seat the pump to tank by pushing the top downward. Make sure the gasket does not slip over the outside or inside edge of the tank lip. While holding the pump in the seated position, place the band clamp over the lip of the tank and edge of the pump. Tighten the band clamp to 31 inch lbs. (4 Nm). Do not over tighten.
  3. Install the fuel tubes over the return and supply nipples on the module.
  4. Connect the vent line to the pressure relief/rollover valve.
  5. Attach the electrical wiring to the pump.
  6. Using a DRB III or equivalent scan tool, pressurize the fuel system.
  7. Check for leaks.
  8. Install the access cover and gasket. Tighten the fasteners.
  9. Install the trunk liner.
  10. Connect the negative battery cable.

Hope this hellps (remeber to rate this answer).

Posted on Dec 17, 2010


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