Chrysler Repair: fuel pump replacement, fuel filler cap, fuel system components


Question
I'm looking for an explanation as to how to replace a fuel pump on a 1997
chrysler LXI 3.8L

Do I have to drop the gas tank, or can I access the pump thru the floor from
above. Pull up or cut carpeting to access a door or an open area to reach the
pump?

Any advice is appreciated.

Thanks

Jeff

Answer
FUEL TANK
Fuel Tank
WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE.

REMOVAL
Disconnect negative cable from battery.
Remove fuel filler cap and perform Fuel System Pressure Release procedure.
Insert fuel siphon hose into fuel filler neck and push it into the tank.
Drain fuel tank dry into holding tank or a properly labeled GASOLINE safety container.
Raise vehicle on hoist.
Disconnect both the fuel fill and fuel vent rubber hoses at the fuel tank.
Disconnect fuel supply lines from the steel supply line.
The fuel pump module electrical connector has a retainer that locks it in place.

Slide fuel pump module electrical connector lock to unlock Fuel Line Retainers and Pump Connector Lock
Push down on connector retainer Pump Module Connector Retainer and Lock and pull connector off module.
Use a transmission jack to support fuel tank. Remove bolts from fuel tank straps.
Lower tank slightly. Carefully remove filler hose from tank.
Lower the fuel tank. Disconnect pressure relief/rollover valve hose at the front of tank. Remove clamp and remove fuel filler tube vent hose. Remove fuel tank from vehicle.
INSTALLATION
Position fuel tank on transmission jack. Connect pressure relief/rollover valve hose. Connect fuel filler tube vent hose and replace clamp.
Raise tank into position and carefully work filler tube into tank. A light coating of clean engine oil on the tube end may be used to aid assembly.
Feed filler vent line thru frame rail. Careful not to cross lines.
Tighten strap bolts to 54 N·m (40 ft. lbs.) torque. Remove transmission jack.
Tighten filler hose clamp to 3.3 N·m (30 in. lbs.)
CAUTION: Ensure straps are not twisted or bent before or after tightening strap nuts.

Connect fuel pump/module electrical connector. Place retainer in locked position.
Lubricate the fuel supply line with clean 30 weight engine oil, install the quick connect fuel fitting. Refer to Tube/Fitting Assembly in the Fuel Delivery section of this Group.
Attach filler line to filler tube. Pull on connector to make sure of connection.
Fill fuel tank, replace cap, and connect battery negative cable
CAUTION: When using the ASD Fuel System Test, the ASD relay and fuel pump relay remain energized for 7 minutes or until the test is stopped, or until the ignition switch is turned to the Off position.

Use the DRB scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.