Dodge Repair: 2001 Dodge Diesel Fuel Pump replacement, fuel tank installation, plastic fuel tank


Question
Can you give me the A-Z on R&Ring the fuel pump on a 2001 Ram 4X4 PU? Also I have been told the lift pump is usually the culprit of the fuel pump going south and it would need replacing also. Comments on that? And can the lift pump be R&Red by a consumer? Thx bunches!!!

Answer
REMOVAL
The fuel transfer pump (fuel lift pump) is located on left side of engine, below and rearward of fuel filter (Fuel Transfer Pump Location).

Disconnect both negative battery cables at both batteries.
Thoroughly clean area around transfer pump and fuel lines of any contamination.
Remove starter motor. Refer to Starter Removal/Installation in 8, Starting System for procedures.
Place a drain pan below the pump.
Disconnect fuel line quick-connect fitting at fuel supply line (Fuel Transfer Pump Location) at rear of pump.
Remove support bracket bolt at top of pump (Fuel Transfer Pump Location).
Remove front and rear banjo bolts at pump (Fuel Transfer Pump Location).
Disconnect electrical connector at side of pump (Fuel Transfer Pump Location).
Remove three pump bracket nuts (Fuel Transfer Pump Location) and remove pump from vehicle.


FUEL TANK MODULE
REMOVAL
Drain and remove fuel tank. Refer to Fuel Tank Removal/Installation.
Thoroughly clean area around tank module at top of tank.
The plastic fuel tank module locknut is threaded onto fuel tank Locknut Removal/Installation - TYPICAL MODULE Install Special Tool 6856 to locknut and remove locknut Locknut Removal/Installation - TYPICAL MODULE The fuel tank module will spring up when locknut is removed.
Remove module from fuel tank.
INSTALLATION
CAUTION: Whenever the fuel tank module is serviced, the rubber gasket must be replaced.

Thoroughly clean locknut and locknut threads at top of tank.
Using new gasket, carefully position fuel tank module into opening in fuel tank.
Position locknut over top of fuel tank module. Install locknut finger tight.
When looking down at tank from drivers side of tank, the arrow at top of module should be aligned between two marks stamped into tank (approximately 2 o'clock position) The fuel line connectors, roll over valve and fuel gauge electrical connector should all be pointed to drivers side of vehicle. Rotate and align module/tank marks if necessary before tightening locknut. This step must be performed to prevent the module's float from contacting side of fuel tank.
Tighten locknut to 24 - 44 N·m (18 - 32 ft. lbs.) torque.
Install fuel tank. Refer to Fuel Tank Removal/Installation.