How to Install a 1999 Dodge Stratus Fuel Pump

Save

The 1999 Dodge Stratus came with either a 2.0-liter four-cylinder engine or a 2.5-liter V-6 and an automatic or manual transmission. The fuel system includes the fuel pump, fuel filter, fuel pressure regulator, fuel rail and fuel injectors. The fuel pump is the life of your fuel system and a faulty pump will render your car useless, until repaired. The fuel pump on your Stratus is located in the fuel tank, which has to be removed to replace the fuel pump. This process is the same for all engine and transmission configurations.

Things You'll Need

  • Wheel chocks
  • Floor jack
  • Jack stands
  • Socket set
  • Ratchet set
  • Block of wood
  • Drain pan
  • 5-gallon gas cans (up to 4)
  • Spanner wrench
  • Inch-pounds torque wrench

Removal

  • Park the vehicle on a level surface and set the parking brake. Lift the vehicle hood and support it with the hood prop rod. Open the cover of the fuse box. Grasp the fuel pump relay firmly and pull it out of its socket. The fuel pump relay is on the far right side of the fuse box, third from the bottom.

  • Start the engine and allow it to run until it stalls out, to relieve the fuel pressure. Turn the ignition key off. Install the memory saver to the cigarette lighter socket. Disconnect the negative batter cable from the battery with the socket and ratchet.

  • Place wheel chocks around the front wheels. Lift the rear of the vehicle into the air with the floor jack and place the jack stands under the rear suspension. Lower the vehicle until it rests securely on the jack stands. Shake the vehicle to ensure it is safe to work beneath it.

  • Open the truck lid and pull back the trunk mat from the left rear corner of the trunk. Disconnect the four-pin fuel pump wiring connector from the vehicle wiring harness. Follow the pump connector back to the rubber grommet in the body. Push the grommet through the body hole, followed by the fuel pump connector. Remove the fuel cap to release any vapor pressure in the tank.

  • Place the drain pan under the tank drain bolt on the left side of the tank. Remove the fuel tank drain bolt with the socket and ratchet. Install the plug when the drain pan becomes full, and pour the fuel from the drain pan into a 5 gallon gas can. Repeat, until fuel no longer drains from the tank. Tighten the drain plug to 32 inch-pounds with the inch-pounds torque wrench.

  • Loosen the fuel filler neck clamp with the screwdriver. Wrap a shop rag around the hose and carefully remove the hose from the tank. A small amount of fuel may drain from the fill neck.

  • Place the block of wood on the jack arm and raise the jack arm until the block of wood contacts the fuel tank. Do not apply any pressure to the tank. Remove the fuel tank strap bolts with the socket and ratchet starting with the passenger side. Remove the tank straps from under the vehicle.

  • Instruct an assistant to help balance the tank and lower the tank enough to access the fuel line and vacuum fittings. Mark each hose and fitting with the tape and marker as they are removed to aid in assembly. Mark and disconnect the vapor purge line; it is on the passenger side of the tank. Squeeze the tabs on the quick connect fittings at the fuel pump and pull the fuel lines off the fuel pump nipples. Mark and disconnect the EVAP canister hoses.

  • Lower the tank to the ground and remove it from under the vehicle. Clean the top of the tank to remove any built up grease or dirt. Place the spanner wrench over the fuel pump lock ring. Install the ratchet to the square hole in the spanner wrench and rotate the lock ring counterclockwise until loose. Remove the lock ring, rubber O-ring and fuel pump module from the gas tank.

Installation

  • Clean the area around the fuel pump module hole and install the new rubber O-ring. Set the new fuel pump module into position, making sure the alignment tab matches the notch in the fuel tank. Install the lock ring over the fuel pump and tighten to 55 foot-pounds with the torque wrench and spanner wrench.

  • Set the fuel tank in position under the vehicle and lift it onto the jack arm and block of wood, with the help of an assistant. Raise the jack arm until the fuel tank lines can be connected. Remove the tape from the fuel vapor line nipple at the rollover valve and connect the fuel vapor line.

  • Remove the tape and install the EVAP hoses. Install the fuel ending and return lines, the small line goes to the small fitting and the large line goes to the large fitting. Push on the line to connect them. View the holes in the fuel line to ensure both tabs are visible through the holes.

  • Raise the jack arm until the tank is in the proper position. Do not apply pressure to the bottom of the tank. Hold the fuel tank straps in place and install the front bolt first, then the rear. Tighten fuel tank strap bolts to 250 inch-pounds with the inch pounds torque wrench.

  • Push the fuel pump connector through its hole in the body and push the grommet into place. Connect the fuel filler neck and tighten the clamp with the screwdriver.

  • Connect the fuel pump connector to the vehicle wiring harness and push the floormat back into place. Shut the trunk lid.. Lift the rear of the vehicle off the jack stands with the floor jack and remove the jack stands. Lower the rear of the vehicle to the ground. Pour the fuel from the 5 gallon gas cans into the fuel tank. Install the fuel fill cap.

  • Push the fuel pump relay into its socket and install the fuse box lid. Turn the ignition key to the “On” position for two seconds and then back to “Off” for 10 seconds. Inspect for any fuel leaks and then start the engine to ensure proper pump operation.

Tips & Warnings

  • Do not smoke or use open flame at any time during this procedure.

References

Promoted By Zergnet

Comments

Related Searches

Check It Out

How To Travel For Free With Reward Points

M
Is DIY in your DNA? Become part of our maker community.
Submit Your Work!