How to Change the Fuel Pump on a 1995 Dodge Neon
Several main components feed fuel to the engine of a 1995 Dodge Neon, including fuel injectors, fuel rail, fuel lines and a fuel pump. The fuel pump is the heart of the fuel system. It pulls fuel from the tank and pushes it through the lines. When this component fails, it produces several noticeable effects. The most common are immediate stalling after starting, random stalling and failure to start. Replacing the fuel pump takes several hours, but doing it yourself is a lot cheaper than having a professional mechanic do it
Other People Are Reading
Things You'll Need
- Floor jack
- Jack stands
- Fuel pressure release hose
- 1/2-inch rubber fuel line (at least 3-feet long)
- Ratchet
- Socket set
- Torque wrench
- Hammer
- Brass drift punch
- 5-gallon gasoline can
- Clean drain pan
Instructions
-
-
1
Open the fuel filler cap of the Dodge Neon to release the pressure from inside the fuel tank. Leave this cap off for the duration of the repair.
-
2
Open the hood and disconnect the negative battery cable, using the ratchet and socket.
-
-
3
Locate the fuel rail. It's a 12-inch long, cylindrical bar on top of the engine.
-
4
Locate the fuel pressure check/relief valve, a short metal valve about 1-inch long, near the center of the fuel rail. It may be covered by a rubber cap. Pull the cap off, if present.
-
5
Place the end of the fuel pressure release hose into the 5-gallon gas can. Place the connector end on the end of the fuel pressure check/relief valve. At this time, the fuel pressure is relieved from the vehicle. Afterwards, you can remove the hose and cap the valve.
-
6
Use the floor jack to elevate the vehicle's rear end. Place the jack stands beneath a secure portion of the rear end. Slowly lower the vehicle until it is supported only by the jack stands and remove the floor jack.
-
7
Crawl beneath the vehicle and locate the fuel pump panel. This panel is located on the very rear of the fuel tank. It is the only part of the tank that contains electrical wires.
-
8
Examine the fuel pump panel and locate the fuel drain tube. It is about 4 inches long tube and is sealed by a rubber cap.
-
9
Place the 1/2-inch rubber hose into the 5-gallon gas can.
-
10
Place the clean drain pan directly under the drain tube. Holding the fuel hose in one hand, quickly remove the rubber cap on the drain tube and press the fuel hose onto the tube, this drains the fuel from the tank and saves it for reuse.
-
11
Remove the fuel hose and cap the drain tube after all of the fuel has drained from the tank. Pour the small amount of fuel from the drain pan into the gas can.
-
12
Disconnect the two fuel lines running into the fuel pump by pressing the locking tabs with you index finger and thumb and pulling off the hose. Some residual fuel may leak out, but this is not a concern. Take note of where each fuel hose was connected because they must be reconnected in the same fashion.
-
13
Remove the fuel pump wiring harness by pressing the locking tab and pulling the wiring harness from the fuel pump panel.
-
14
Examine the fuel pump panel and locate the locking ring. It is the center-most, metal ring holding the pump panel in place. It has notches. These are used to turn the ring.
-
15
Place the brass drift punch -- basically a center-punch with a flat surface -- in one of the notches on fuel pump ring and lightly tap the drift with a hammer to turn the locking ring counterclockwise until it is unlocked.
-
16
Pull the fuel pump panel from the fuel tank. Remove the old o-ring -- a circular rubber gasket -- from the tank if it does not come off with the pump. The pump comes out as a large assembly which includes the pump, strainer, fuel level sender and pressure regulator.
-
17
Place the new o-ring on the fuel pump as instructed by the paperwork included with the pump. The o-ring is included with the new fuel pump module.
-
18
Insert the fuel pump module into the fuel tank.
-
19
Install the locking ring on the fuel pump. Tap it clockwise using the brass drift and a hammer until it locks into place.
-
20
Plug in the fuel pump wiring harness. Listen for a clicking sound indicating that it's locked in place.
-
21
Press the fuel hoses onto the new fuel pump panel inlets in the same fashion they were on the old pump. A clicking sound indicates the hoses are locked in place.
-
22
Lift the vehicle with the floor jack and remove the jack stands.
-
23
Lower the vehicle to the ground.
-
24
Fill the fuel tank with the fuel recovered in the 5-gallon fuel can.
-
25
Screw the fuel filler cap back on the Neon. Replace the negative battery cable and close the hood.
-
1
Tips & Warnings
Do not be alarmed it your Dodge Neon does not start on the initial try. You may need to prime the fuel lines by cycling the key "On" and "Off" a few times.
The 1995 Neon is equipped with an 11.2-gallon fuel tank, so multiple gasoline cans may be needed when draining the fuel. (Ref 4)
Never smoke or use an open flame while performing this repair, as gasoline vapor can ignite.
Never perform this repair with the battery connected as a single spark can ignite the fuel.
Always use a brass drift. A steel one can create sparks and ignite a fire.
