Replacing The Fuel Pump In A Chrysler Town And Country

Replacing the fuel pump in a 2000 Chrysler Town and Country is a complex task that requires specific tools and a good deal of automotive repair knowledge. The fuel pump is located inside the fuel tank, so the first steps involve relieving pressure from the system and disconnecting the battery and various hoses and lines to access and remove the tank. Once the tank is lowered, the fuel pump lock ring must be removed with a brass punch, and the pump module can be taken out. A new pump can then be installed, and the fuel tank and all disconnected parts reattached.

Release fuel system pressure and disconnect the negative battery cable

To release the fuel system pressure and disconnect the negative battery cable of your 2000 Chrysler Town and Country, follow these steps:

First, locate your car battery. Most vehicles have them bolted in place under the hood. If you've never raised your vehicle's hood before, check your owner's manual. It will tell you how to do it and where the safety catch is.

Once you've located the battery, identify the positive and negative terminals. The positive terminal is marked with a "+" sign, while the negative is marked with a "-" sign. Be sure to exercise caution and wear eye protection when working around the battery.

Now, we will release the fuel system pressure. This is a crucial step to ensure your safety and prevent fuel spray. Here are the steps:

• Remove the CIRCUIT RELAY. It is located in the larger of the two plastic fuse boxes near the battery and is labeled "CIRCUIT RELAY" on the top of the fuse box.
• After the engine stalls, turn off the ignition switch.
• Install the circuit-opening relay.
• Remove the gas cap to depressurize the fuel tank.

Use a rag to protect yourself from any fuel spray when disconnecting the hoses, and be sure to plug the hoses after removal.

Next, we will disconnect the negative battery cable:

• Unbolt the negative battery cable. Be sure that the ignition is off before proceeding.
• Disconnect the negative cable by lifting it free. It may require some wiggling and twisting.
• Ensure that the wrench does not touch both the negative and positive terminals simultaneously to avoid creating a spark.
• Move the negative cable away from the battery.
• Now, disconnect the positive cable.

By following these steps, you will have successfully released the fuel system pressure and disconnected the negative battery cable on your 2000 Chrysler Town and Country.

Remove the fuel tank and disconnect the fuel line

To remove the fuel tank and disconnect the fuel line of a 2000 Chrysler Town and Country, follow these steps:

Firstly, relieve the fuel system pressure and disconnect the cable from the negative terminal of the battery. Then, loosen the left rear wheel lug nuts and raise the rear of the vehicle, placing it securely on jack stands. Remove the left rear wheel.

Now, locate the fuel tank filler neck vent tube inside the left rear wheel well and disconnect the two-tab type quick-connect fitting. Disconnect the fuel tank filler hose from the metal tube at the upper end of the hose, not from the fuel tank itself. Disconnect the fuel line quick-connect fitting and the EVAP line quick-connect fitting, both of which are located at the front of the fuel tank.

Next, disconnect the electrical connector from the fuel pump/fuel level sending unit. Support the fuel tank with a transmission jack or floor jack and remove the fuel tank strap bolts. Carefully lower the fuel tank from the vehicle.

To disconnect the fuel line, use a 5/16" quick-disconnect tool and slide it up into the fuel rail hose to pull the lines apart.

Remove the fuel pump lock ring and take out the pump module

To remove the fuel pump lock ring and take out the pump module of a 2000 Chrysler Town and Country, you will need to perform the following steps:

Release the fuel system pressure

The fuel system is under constant pressure, even when the engine is off. Always release the fuel pressure before servicing any fuel system component.

Remove the fuel tank

The fuel tank must be removed prior to servicing the fuel pump. This will involve raising the vehicle, draining the fuel tank, removing the filler tube, disconnecting electrical connectors, and lowering the tank.

Loosen the fuel pump lock ring

Using a non-ferrous tool, such as a brass punch or a specially designed wrench, carefully tap or rotate the fuel pump lock ring counter-clockwise to release it. This will require some force, but be careful not to overtighten as the fuel pump seal could split and leak.

Remove the fuel pump and its O-ring

With the lock ring removed, carefully take out the fuel pump and its O-ring from the fuel tank. Discard the old O-ring and cover any tank openings to prevent dirt from entering the system.

Now that the fuel pump lock ring has been removed, you can proceed to take out the pump module. Here are some additional steps to complete the process:

Clean the fuel tank

It is recommended to clean the inside and outside of the fuel tank before installing the new pump. Use a mild detergent and water for the outside, and an appropriate tank cleaning solution for the inside, even if the fuel pump strainer does not show contaminants.

Install the new tank seal and slide in the new pump module

Install a new tank seal and carefully slide the new pump module into the tank, ensuring that the locating tab sets between the retainers on top of the tank. Be careful not to bend the spring-loaded assembly.

Secure the pump module with the lock ring

Put the locking ring back in place and compress the spring slightly. Using your non-ferrous tool, turn the locking ring clockwise to lock the module securely in place.

By following these steps, you should be able to successfully remove the fuel pump lock ring and take out the pump module on your 2000 Chrysler Town and Country.

Clean the inside of the tank and install a new tank seal

To clean the inside of the tank of your 2000 Chrysler Town and Country, you will first need to drain all the fuel from the tank into an approved container or fuel caddy. Next, drop the tank by following the instructions in your service manual. Once the tank is dropped, clean the area from which the pump is being removed with a brush. Now, insert a hose into the fuel tank and pour a stream of clean, hot water into the tank. While the tank is filling, spray a mild detergent inside. If the tank opening allows, use a brush to loosen debris from the sides of the tank.

Once done, stop the stream of water and swish the water around to capture all debris. Dump the dirty water into a pan, capturing any liquids. Wipe the tank with a lint-free washcloth and dry it completely with compressed air. Inspect the tank for rust or physical damage; if present, the tank must be repaired or replaced. Finally, add fuel line antifreeze/water remover to the tank to absorb any residual moisture. Let the tank dry for 30 minutes before proceeding with the installation of the new tank seal.

To install the new tank seal, first wipe the seal area of the tank clean and install a new O-ring seal on the pump. Position the fuel pump module in the tank and secure it with the lock-ring. Using a hammer and a brass drift, carefully tap the fuel pump lock-ring clockwise to lock the module in place. Do not overtighten the lock-ring, as the fuel pump seal could split and leak.

Install the new fuel pump and lock ring

To install the new fuel pump and lock ring, first, install the appropriate tank seal and slide it into the tank. Be careful not to bend the arm. This spring-loaded assembly needs to be inserted in a way that the locating tab sets between the retainers on top of the tank. Once the pump is installed, put the locking ring back in place. While compressing the spring slightly, start the locking ring and turn it clockwise with a nonferrous brass punch.

Now, install the new fuel filter. Next, lift the tank and insert the vent hose through the frame port and start the fuel filler hose. Connect the fuel line going to the engine and the electrical connector. Slide the safety retainer into position and install the tank strap. Tighten the hose clamp on the filler hose, reinstall the emissions tubes, and put the shield back around them. Ensure the static ground strap is repositioned on the tank strap. Reconnect the negative battery cable.

Cycle the key 2-3 times to charge the system. Always monitor the fuel pressure once the vehicle is started to ensure it’s within specifications. Afterward, remove the gauge, turn off the engine, and bleed the pressure from the system using the pressure relief on the gauge. Make sure to capture any fuel in a safe container.

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