Replacing The Fuel Pump On A 1999 Dodge Stratus

If you're looking to replace the fuel pump on your 1999 Dodge Stratus, you'll first need to determine whether your car is a 4-door or 2-door coupe model. This is because the fuel pump on a 4-door Stratus is located inside the fuel tank, whereas the 2-door coupe model has an access panel for the pump under the rear seat.

If your Stratus is a 4-door, you'll need to remove the fuel tank, the lock ring, and then the pump. It's a tricky job and is best performed at a dealership's service department.

If you have a 2-door coupe, you'll need to remove the rear seat to access the pump.

Removing the fuel tank

To remove the fuel tank from a 1999 Dodge Stratus, you will first need to release the fuel system pressure and disconnect the negative cable from the auxiliary jumper terminal. Next, from inside the trunk, disconnect the pump wiring jumper from the main body harness. The 4-pin connector is located under the trunk mat on the left side of the trunk near the base of the shock tower.

Now, locate the body grommet for the jumper near the base of the rear seat. Push the grommet out and feed the jumper completely through the hole in the body. Remove the fuel cap slowly to release tank pressure.

With the vehicle on a hoist, drain the fuel from the tank. Support the fuel tank with a support such as a transmission jack stand. Position a fuel-approved container (with a capacity of at least 16 gallons) under the drain plug located on the bottom left edge of the tank. Remove the drain plug and allow the fuel to drain. When the tank is no longer draining, install the drain plug and tighten it to 32 in-lbs.

Disconnect the fuel tank from the rubber fill hose. Wrap shop towels around the hoses to catch any gasoline spillage. Disconnect the fuel lines from the fuel pump module. These are quick-connect fittings. Disconnect the vapor line from the tank-mounted rollover valve. The valve is located at the rear of the tank and connects to the vapor line with a rubber hose.

Now, remove the bolts and fuel tank straps. Finally, remove the tank from the vehicle. Slide the tank forward during removal to allow the fill neck to clear the suspension cross-member.

Disconnecting the fuel filter lines

Before beginning, it is important to ensure your safety and the protection of your vehicle. Make sure you are wearing appropriate protective gear, including gloves and eye protection. Work in a well-ventilated area and avoid any sources of ignition, such as smoking. It is also crucial to release the fuel system pressure before starting.

Step 1: Remove the fuel filler cap and perform the Fuel System Pressure Release procedure. Refer to your vehicle's service manual for detailed instructions on this procedure.

Step 2: Disconnect the negative cable from the auxiliary jumper terminal. This will prevent any accidental electrical discharge during the process.

Step 3: Remove the fuel tank. Refer to your vehicle's repair manual for specific instructions on how to safely remove the fuel tank, as it may involve additional steps and precautions.

Step 4: Disconnect the fuel filter lines from the fuel pump module. This step may require some force, but be careful not to damage the lines or the surrounding components.

Step 5: Clean the top of the fuel tank to remove any loose dirt or debris. This step is important to prevent any contaminants from entering the fuel system and causing issues.

Step 6: Using a specialized tool, such as a fuel pump module ring spanner, remove the locknut that secures the pump module in place. Be cautious, as the fuel reservoir may still contain fuel, and it may spill out when the module is removed.

By following these steps, you can safely and effectively disconnect the fuel filter lines when replacing the fuel pump on your 1999 Dodge Stratus. Remember to refer to your vehicle's service manual for additional information and always prioritize your safety during the process.

Cleaning the tank

To clean the tank of your 1999 Dodge Stratus, you will first need to depressurise the fuel system. Start by removing the fuel cap. Then, open the trunk and locate the fuel pump electrical connector. Unplug it from the wiring harness and feed the wires and connector through the hole near the rear seat. Next, start the engine and let the car run until it uses the remaining fuel in the line and dies.

Now, open the hood and disconnect the negative battery cable. Raise the vehicle and support it with jack stands. Place a container under the gas tank drain plug and remove the plug to allow the remaining fuel to drain. Return the drain plug and tighten it.

Loosen the clamp that holds the fuel neck filler hose to the fuel tank and remove the hose from the tank. Disconnect the fuel line from the fuel pump assembly and the small, rubber vapor hose attached to the rear of the fuel tank.

Place a floor jack under the tank and raise it until it is supporting the tank. Remove the bolts holding the fuel tank straps to the vehicle frame and remove the tank from underneath the vehicle.

Before removing the fuel pump, clean the area around the fuel pump assembly to avoid contaminating the tank.

Removing the locknut and pump module

To remove the locknut and pump module from your 1999 Dodge Stratus, you will first need to remove the fuel filler cap and perform the Fuel System Pressure Release procedure. You can refer to your Dodge Stratus manual for the procedure.

Next, disconnect the negative cable from the auxiliary jumper terminal. Then, remove the fuel tank by referring to the Fuel Tank/Service and Repair manual. Once the fuel tank is removed, disconnect the fuel filter lines from the fuel pump module.

Clean the top of the tank to remove any loose dirt and debris. Using Special Tool #6856 Fuel Pump Module Ring Spanner, remove the locknut to release the pump module. Be cautious as the fuel in the reservoir may spill out when the module is removed.

Finally, remove the fuel pump module and O-ring from the tank. Discard the old O-ring and replace it with a new one during installation.

Installing the new pump module

To install the new fuel pump module on your 1999 Dodge Stratus, follow these steps:

First, wipe the seal area of the tank clean. Place a new O-ring on the ledge between the tank threads and the pump module opening. Position the fuel pump module in the tank, ensuring the alignment tab on the underside of the pump module flange sits in the corresponding notch in the fuel tank.

While holding the pump module in position, install the locknut. Tighten the locknut to 40 ft-lb torque using a special tool.

Next, install the fuel tank and fuel filter. Refer to your vehicle's service manual for detailed instructions on this step. Fill the fuel tank with clean fuel and check for leaks.

Finally, install the negative cable to the auxiliary jumper terminal.

It is important to note that over-tightening the pump lock ring may result in a leak. Always refer to the manufacturer's instructions or a trusted mechanic if you are unsure about any steps in the process.

Frequently asked questions