How to Disassemble a Fuel Filter on a Dodge Caravan

The fuel filter on a Dodge Caravan is part of the fuel pump module located inside the fuel tank. If the filter is torn or damaged, you need to replace the module and filter as an assembly. If your Caravan comes equipped with a fold-in-floor seat, make sure you have the special tool to unlock the fuel module from the tank. See the Resources box at the bottom for more information.

Things You'll Need

• Wrench
• Hand siphon pump, if necessary
• Floor jack
• Two jack stands
• Ratchet
• Ratchet extension
• Socket
• Soft brush
• Shop rag
• Brass punch, if necessary
• Hammer, if necessary
• Fuel tank lock ring wrench, if necessary
• New O-ring seal

Instructions

Relieving the Fuel System Pressure

1. Locate the Power Distribution Center (PDC) on the driver side in the engine compartment and remove the fuel pump relay from the PDC.

2. Start the engine and let it idle until it stalls. Try to start the engine again to remove any fuel pressure remaining in the system. Turn the ignition key to the Off position.

3. Detach the ground (black) battery cable using a wrench.

Removing the Fuel Tank Module

1. Loosen the fuel filler cap to release the fuel pressure inside the tank. Drain the fuel tank into an approved container; if more than 1/4 full, using a hand siphon pump.

2. Lift the rear of your Dodge vehicle using a floor jack and support it on two jack stands.

3. Support the fuel tank with the floor jack. Unscrew the fuel tank straps using a ratchet, ratchet extension and socket.

4. Lower the fuel tank just enough to reach the electrical connector and hoses connected to the fuel pump module on the front of the fuel tank. Disconnect the fuel and vapor lines by squeezing the tabs and the fuel pump module electrical connector.

5. Lower the fuel tank to the floor. Clean the area around the top of the fuel pump module to keep dirt and debris from falling into the tank after you remove the module. Use a soft brush and a shop rag.

6. Release the fuel tank module locking ring by rotating the ring with a brass punch and a hammer, if your Caravan is not equipped with a fold-in-floor seat, or a lock ring wrench (special tool #9340), if your Caravan is equipped with a fold-in-floor seat. See the Tip box at the bottom for more information.

7. Pull the fuel tank module and O-ring seal from the fuel tank.

Installing the Fuel Tank Module

1. Set the new fuel tank module in place using a new O-ring seal.

2. Secure the fuel tank module to the tank by rotating the ring with the brass punch and a hammer, if your Caravan is not equipped with a fold-in-floor seat, or the lock ring wrench (special tool #9340), if your Caravan is equipped with a fold-in-floor seat.

3. Raise the fuel tank using the floor jack just enough to connect the hoses and electrical connector. Connect the fuel and vapor lines and the fuel pump module electrical connector.

4. Raise the fuel tank to its mounting position. Screw the fuel tank straps using the ratchet, ratchet extension and socket.

5. Remove the floor jack and lower your vehicle.

6. Refill the fuel tank, tighten the fuel filler cap and connect the fuel pump relay.

7. Attach the ground (black) battery cable using the wrench.

Tips & Warnings

• Many auto parts stores have special tools available for rent. Check your local auto parts outlets for the locking ring tool before buying one.

• After removing the fuel pump relay, the Power Control Module on your Dodge Caravan may have stored one or more Diagnostic Trouble Codes (DTCs). You can erase these codes using a scan tool. If necessary, consult your car owner's manual or follow the instructions in your tool manual.

References

• Dodge Caravan, Chrysler Voyager & Town & Country 2003 thru 2006 (Haynes Repair Manual); John A. Wegmann and John H. Haynes; 2007

Resources

• Fuel Tank Lock Ring Wrench